Diesel Engine Performance
As promised in a previous issue, here’s the Diesel Performance Buyer’s Guide, chock-full of tips and tricks, as well as product.

Text: Jim Allen
Photos: Jim Allen

Naturally Aspirated (NA) Diesel Performance
Methods of increasing available airflow to a diesel engine are a lot like what you are used to with gas engines. They start with free-flow air filters (elements and housings), cool air intakes and exhaust improvements. Free-flow exhausts are available for nearly all American NA light truck diesels, such as the Banks Stinger kits for the GM 6.2L and Ford 6.9/7.3L NA units, and headers are available for some. In some cases, there are better intake manifold choices that can allow breathing improvements. Any breathing improvements allow you to add more fuel for more power.

Adding turbocharging to any NA engine produces dramatic power increases if the fuel rate is increased to match. Yes, a turbo kit is pricey, but you can spend an equal amount on improving NA performance and not get half the benefit. As one diesel engineer said, “There ain’t no good excuse for a naturally aspirated diesel.”

Banks Sidewinders
If you drive a GM 6.2L or a Ford 6.9/7.3L NA engine, you know about life in the slow lane. When climbing a hill of any size, you’re in the slow lane at 40 mph blowing huge clouds of black smoke. Help is available in a big way. You can bolt on a Banks Sidewinder Turbo kit and pump your 6.2L up from135hp and 240 lbs-ft of torque to 200+ hp and nearly 400 lbs-ft or torque with the non-wastegated Sidewinder. On the 6.9L/7.3L Fords, power jumps from 170/185 hp and 315/345 lbs-ft to up to about 264 hp and 503 lbs-ft for the wastegated Sidewinder system (the 6.9L will be a less). The kits include the turbo and manifolding, low restriction air filter assembly and a 3.0 or 3.5 inch exhaust system. Contact Banks • 800-601-8072 • www.bankspower.com

Turbo Diesel Performance
Many indirect injection (IDI) turbo diesels run at fairly low boost levels, so increasing boost and fuel rate seems an obvious method of increasing performance. Boost can be slightly increased in some turbo diesels via exhaust improvements. Backpressure is often used to limit maximum boost. In some cases, most notably early Ford 7.3L IDI and GM 6.5L turbo diesels, the pipe, just downstream of the turbo, is crushed to reduce flow. By installing an aftermarket replacement pipe, the turbo definitely spools up faster and may offer an increase in max boost.

By delaying wastegate opening, you can encourage a little more boost. In the early turbo diesels, before electronic controls, this could be done by adjustments to the wastegate linkage. All the latest diesels are electronically controlled, so any major changes in boost will come from a chip change. Any increases in boost above 12psi (accompanied by a proportional fuel rate increase) should be accompanied by the installation of an intercooler. If your rig already has an intercooler, and you increase your boost and fuel rate by a large amount, you might need to install a larger intercooler.

The method of increasing fuel rate varies according to injection type. The straight mechanical injections, such as the older Ford, GM and Cummins engines are adjustable to a degree and can be set to accompany improvements in breathing. When the limits of adjustment are reached, the only upgrades are modified/higher capacity pumps and/or increased flow injectors. The electronic engines require changes in programming to increase fuel rate, which works up to the point where injector flow is maxed out, then higher flow injectors are needed.

Bully Dog Rapid Flow Intake
Most OE intake systems are restrictive to a degree and the primary culprit is usually the filter and housing. Bully Dog offers a very cost effective improvement for the ’03-04 Dodge Cummins, ’03-04 6.0L Powerstrokes and ’01-04 6.6L Duramax engines. Airflow is improved 200-300 percent! These units are ducted to cool air and installation is as little as 15 minutes. This improvement could be used to enhance other mods as well. The cotton gauze filter is a permanent unit that can be cleaned and re-oiled for a lifetime of service. Contact Bully Dog • 866-285-5936 • www.bullydog.com

(TO ORDER CALL 4 WHEEL PARTS AT 800-284-9840

Banks Monster Exhaust
Breathe in, breathe out. Both are keys to diesel performance. Banks 4-inch Monster exhaust systems are available for several late model diesels, including this one for the 6.0L Powerstroke Ford Excursion. It’s a mandrill bent, stainless steel system that includes a 5-inch polished stainless tip. Benefits include a power increase, lower EGTs and better fuel economy. This monster will also enhance existing or future performance improvements. Contact Banks • 800-601-8072 • www.bankspower.com

Bully Dog Rapid Flow Exhaust
The higher up the performance ladder your diesel goes, the more exhaust flow is needed. Bully Dog produces 4, 5 or 6-inch diameter mandrill bent exhaust systems that fit most recent diesel applications. They come in low cost 16 gauge aluminized steel or T-304 stainless. These systems are claimed to drop EGT by as much as 200 degrees, and, of course, the power benefits are obvious. These are a must-have to get the most out of other performance improvements. Contact Bully Dog • 866-285-5936 • www.bullydog.com

Edelbrock Diesel Exhausts
Edelbrock might not be the first name you think of when it comes to diesel engine performance, but they have been number one in the hotrodding world for nearly half a century. When their massive R&D facility and human brain trust was turned to the diesel side of performance, some remarkable things were bound to come out it. Offered for GM Duramax trucks from ’01-current, Dodge Cummins 24 valve trucks from ’98-03, 7.3L Ford Powerstrokes ’99-02 and 6.0L Powerstrokes from ’03, these newly developed systems are mandrill bent, 4-inch systems with Edelbrock’s chambered muffler. With no other mods, this system offered a 17 hp gain on a late model Powerstroke. If you factor in fuel system mods, the Edelbrock system will be a springboard for many more ponies. Contact Edelbrock • 800-416-8628 • www.edelbrock.com

Banks Git Kit
The Git Kits from Banks offer a cost effective first step on the diesel modification chain. They hit the high spots for the particular year and model of diesel truck. The kit shown is for ’94-97 Powerstrokes and offers up to 40hp and 72 lbs-ft of torque, as well as higher boost levels and lower EGTs. It includes a new chip, and a new turbo outlet pipe. Similar kits are available for other popular diesel trucks. This is a great option for people who need a safe boost in towing power without exceeding the limits of the truck’s other systems Contact Banks • 800-601-8072 • www.bankspower.com

Gibson Performance Exhaust
Gibson offers performance exhaust systems for many diesel applications. These include the ’94-04 GM trucks, the GM Duramax, the ’89-04 Cummins Dodges and the ’94-04 Powerstrokes They can be ordered in aluminized or stainless steel and some have the option of the Dual Sport system as shown. They are large diameter, high-flow mandrill bent systems with a distinctive throaty sound. Contact Gibson • 800-528-3044 • www.gibsonperformance.com

Edge Juice Modules/Attitude Controller
Edge Products has a line of modules for Ford, Dodge and GM electronically controlled diesels that will allow five power levels and can feature an in-the-cab adjustment knob when combined with the optional Attitude controller. Shown is the ’01-04 Duramax module that adds power in five increments from 40 to150 hp and 180 to 350 lbs-ft of torque. The Attitude controller allows you to switch between these settings from the driver’s seat according to need. In addition, the controller provides real time monitoring of boost, engine temp, EGT, percent of engine load and other values (according to vehicle). You can custom tune the unit to display the values you are most interested in monitoring. In addition, you can set the unit to control maximum critical values, such as max EGT, boost and transmission slip by defueling the engine when they are reached. Contact Edge • 888-360-EDGE • www.edgeproducts.com

Bully Dog Duramax Power Pup Programmer
The Power Pup is touted as the only downloader with three power settings and the option of a fourth. The unit works on ’01 to current Duramax diesels and offers the choice of 50, 70 or 95 hp increases with an optional 150 hp increase also available. It can also raise the rpm limit, eliminate the speed limiter and correct the speedo after tire or gearing changes. The beauty of this level of choice is that the engine can be tuned for heavy loads safety or for light load max performance. The level of tune can be adjusted to other mods made to the engine.
Contact Bully Dog
• 866-285-5936
• www.bullydog.com

Hypertech Diesel Programmer
Hypertech takes a little different look at diesel performance. Instead of developing their products to merely develop the maximum power possible, they built them to develop maximum sustained power at the truck’s rated Gross Combined Weight Rating. That means you can crank on your truck with a full load and not worry about cooking it. Available for ’98-02 Cummins Dodge 24-valve, ’01-04 GM Duramax and ’99-03 Ford Powerstroke 7.3L engines, the Hypertech programmer has three power increase levels, ranging from a low of about 30-56hp to a high of 100hp. Depending on the truck, there may be other tuning options available, including altering automatic transmission shift firmness and speedometer calibration. The units also clear and store diagnostic trouble codes. Contact Hypertech • 901-382-8888
• www.hypertech.com

Banks Six Gun Diesel Tuner and Speed Loader
The Six Gun tuners are available for the latest common rail, EFI diesels; the ’03-04 Cummins, ’01-03 Duramax and ’03-04 6.0L Powerstroke. At the twist of a dial, there are six levels of power; stock, 20 percent, 40 percent, 60 percent, 80 percent and 100 percent. Intake and exhaust enhancements are recommended. It can be combined with Banks’ Speed Loader that offers even more increases. One of the unique features of the Six Gun is its ability to protect your engine and truck. It will automatically back off power output if it detects excessive EGTs, transmission slip or overboosting. It also has a Failure Modes Effects Analysis, which ensures that the Six-Gun will not adversely affect the onboard electronics. The Speed-Loader addition needs airflow enhancements to gain the full benefits.
Contact Banks • 800-601-8072 •
www.bankspower.com

Bully Dog Sled Dog Tow Packages
These kits give you all you need for maximum performance when towing. Available for the 6.0L Powerstroke and the ’03-04 Cummins, it includes a 4-inch rapid flow exhaust, RFI cold air intake, the Torque Dog or Power Hound computer module and boost and pyrometer instrumentation. With the Powerstroke, Bully Dog recorded 415 hp and 675 lbs-ft of torque on a chassis dyno. No Cummins dyno numbers are available yet, but Bully Dog’s test truck dropped a shade under 5 seconds on the “solo” 0-60 time and nearly 12 seconds when towing 12,000 pounds. These kits are totally suitable for maximum performance towing. Contact Bully Dog • 866-285-5936 • www.bullydog.com

Banks Power Pack
The biggest bangs for the Bank’s bucks are the company’s Power Pack Systems. Power Packs are available for the popular, previous generation Turbo Diesel systems, which include the ’94-02 Powerstrokes and ’89-02 Cummins. They include low restriction, mandrill bent 3.5-inch exhaust systems free flow intakes, electronic modules where applicable and boost and pyro gauges. Variable items according to application can include new turbo housings, intercoolers or larger intercoolers, intake manifolds, wastegate actuators and fuel calibration plates. Torque and power outputs vary greatly according to the exact application, but are substantial, running as much as a 75 percent improvement in torque. Shown is the ’98-02 Cummins Power Pack.

Banks Six Gun Bundle
With the new Six Gun Tuner and Speed-Loader out for the new common rail diesels, it made sense to offer a complete kit for maximum performance. These new kits include the Monster exhaust system, a free flow air filter and the Six Gun Tuner Dyna-Fact pyro and boost gauges. Other items vary according to application, but could include a new wastegate actuator or a larger, high flow intercooler. Optional is the Speed-Loader. The power and torque outputs are truly phenomenal. The top power increases are as follows: Duramax- 128 hp/345 lbs-ft (155 hp/385 lbs-ft w/Speed-Loader), ’03-04 Cummins- 105 hp/258 lbs-ft (126 hp/290 lbs-ft w/Speed-Loader), and ’03-04 6.0L Powerstroke- 115 hp/206 lbs-ft (138 hp/231 lbs-ft w/Speed-Loader). Contact Banks • 800-601-8072 • www.bankspower.com

Propane, Nitrous Oxide and Diesel Performance
Two fairly new players in the diesel performance realm are propane injection and nitrous oxide systems. Introducing propane vapor (never liquid!) into the diesel combustion process serves as a diesel catalyst, causing the fuel to burn more completely. The smoke level is dramatically reduced and exhaust gas temperatures (EGTs) are lower for the horsepower produced by some 5-10 percent. Power increases can be large, depending on the amounts of propane added with 80-150 extra hp possible depending on the system and the type of engine and other mods done to enhance it. Diesel fuel economy can increase also, and even though you are trading diesel fuel for propane, overall economy (dollars per mile) can increase by as much as 20 percent.

A propane system is a good choice for day to day use because it will add power even at normal, non-smoky air/fuel ratios. Some systems can be used with both turbo and-non turbo engines and others are designed only for turbo diesels. The most benefit comes from older generation diesels whose injection systems have fuel rate limitations that are not easily remedied. The newer diesels will still gain, but there are easier and cheaper ways to get the equivalent amount of horsepower. As to nitrous oxide, yes, it works in diesels just like it does in a gas engine. It both cools and highly oxygenates the incoming air, so if you add extra fuel, you get proportional results. In diesels, it’s really only useful if you are in an overfueling condition (lots of black smoke), which is not practical for day to day situations. Some diesel hotrodders deliberately overfuel and add nitrous so that the extra fuel can be turned into power. It’s a definite yeeha moment that can offer 150-250 hp + in short spurts! If you have your air and fuel balanced (very little smoke), nitrous won’t give you much extra kick. Adding nitrous to an engine that is not overfueled is basicly a waste.

Bully Dog Propane Injection Kit
The Bully Dog Propane Injection kit offers an honest 80hp boost, improved diesel fuel economy and less smoke. In addition, your engine will build up less carbon and keep the oil cleaner. The kit includes a regulator, wiring hoses and mounting hardware. You buy a liquid feed tank and install it in the best spot. Features include a dash mounted on-off switch and connections to the engine’s cooling system that warms the incoming propane to ensure 100 percent vapor delivery.

Bully Dog Nitrous Oxide Injection
If your injection system is set up to pour enough fuel, Bully Dog’s nitrous systems can offer up to 250 extra hp in short spurts. These nitrous systems are useful in terrorizing Corvette and muscle car owners, whose eyes will pop when your behemoth diesel picks up and leaves them in the dust. Three systems are offered, the 150hp Bully Kicker with a single nozzle and 125 solenoid, the 200hp Dual Shot, with two nozzles, a .063 solenoid and a .125 solenoid, and the Race Kit, another two nozzle setup with a .125 and a .157 solenoid. The size of the solenoid dictates the nitrous flow. All kits come with 15 pound bottles. Contact Bully Dog • 866-285-5936 • www.bullydog.com

Other Mods
In this category are performance monitoring gauges, tranny improvements and exhaust brakes. None of these items produce any extra power, but make life better in general and help your truck stay in one piece longer.

Bully Dog Allison Shift Enhancer
GM’s Duramax can produce a major amount of torque when modified to the max (Duramax? Pun intended!). Bully Dog’s shift enhancer increases line pressure and speeds up the shift, all of which reduces slippage and allows the clutches to hold more torque. This kit fits 1000, 2000 and 2400 series Allisons and will support an extra 50hp and 100 lbs-ft of torque measured at the rear wheels.

Bully Dog Allison Transmission Upgrade
Bully Dog’s shift enhancer can support a 50 rear-wheel hp increase (over the stock about 250), but then what can you do? Given that the Duramax can crank out 350 rear wheel hp quite easily and a lot more than that if you work it, you might well find yourself with Fricassee ala Allison beside the road one day. The cure is one of Bully Dog’s upgraded Allison trannies. With increased clutch capacity, special valve body and line pressure mods and a new converter, torque capacity is increased 244 percent and Bully Dog will guarantee the tranny to hold 550 rear wheel hp. Contact Bully Dog • 866-285-5936 • www.bullydog.com

Banks Billet Torque Converter
Large power increases will change converter performance, as well as subject the OE converter to loads the engineers didn’t plan for. This problem is now solvable for ’94-02 Dodge Cummins trucks, and ’94-03 Powerstrokes in the form of a billet converter. The forged billet steel housing is only part of the enhancements. The stator, turbine and impeller are superstrengthed and tuned to offer a lower stall speed with modified high output engines... and that decreases slippage and lowers trans temps. The lockup clutch has also been modified for more holding power and features carbon-ceramic material for the ultimate in strength and durability. Banks also offers shift kits that will take better advantage of the benefits offered by the billet converter. Shown is the Dodge 47RE kit.

Banks Trans Command
While the on board electronics of Ford E4OD and 4R100 equipped trucks adjust somewhat to varying loads and conditions, it’s generally off in it’s own little programmed world and ignoring the needs of the performance diesel owner. Most people think the average truck tranny shift is on the mushy side anyway, but when engine power is increased, it gets more so. and may even slip under a heavy load. Bank’s Trans Command modules tighten up the shifts in all modes, reducing slippage and heat. It can differentiate between light loads and gentle driving and hard acceleration or heavy loads and adjusts the shifts accordingly. These modules are available for Ford trucks with E4ODs and 4R100s.

Banks Brakes
Ah, the smell of toasted brakes! If you tow regularly with your diesel truck, especially in mountainous terrain, you may have experienced that unique odor. Hopefully it wasn’t accompanied by the adrenaline charged experience of faded brakes. Because they are unthrottled, diesels produce very little engine braking, so you get less effect from lifting off the throttle or downshifting than you would from a gas engine. There are equalizers out there in the form of exhaust brakes. These devices feature a flapper valve that closes off the exhaust. These are nothing new, but Banks takes the idea a few steps farther by offering computerized controls that integrate with the engine’s control system to automatically brake when needed. The kits will fit stock trucks or rigs modified with Bank’s systems. They have kits to fit a wide variety of applications, old and new.

Banks DynaFact
A pyrometer (Exhaust Gas Temperature) and boost gauge should be on every turbo diesel. They are useful to monitor how hard the engine is working so you can back off to avoid damage. They are also useful as an engine performance tuning tool. If your truck doesn’t have one, you need one. ‘Nuff said. Towing puts very high loads on an automatic, so a trans temp gauge is a vital durability element. If you tow, you need this monitor to avoid frying your automatic. Engine oil temp is a bit less vital in ordinary circumstances, especially since most of the OE diesels have a built in oil cooler. Still, a modified engine can really cook the oil beyond the ability of a factory cooler. Monitoring oil temp enables you to back off before you destroy that vital element, the engine’s life blood, motor oil. Contact Banks • 800-601-8072 • www.bankspower.com