For diesel vehicles, air intake is as vital as breathing is for humans. A well-designed air intake system can greatly enhance engine performance, improve fuel efficiency, and unlock additional horsepower. This guide focuses on upgrading the air intake system for 6.7L Cummins engines, breaking down each component and its impact on overall performance.
Introduction
The air intake system plays a critical role in the operation of diesel engines, including the 6.7L Cummins. By upgrading key components of the intake system, you can significantly improve airflow, increase horsepower, and enhance fuel efficiency. This guide outlines the core components of the air intake system and explores how each upgrade contributes to engine performance.
Let’s dive in and learn step by step how to optimize your air intake system.
Initial Intake and Air Guidance
The first step in the air intake process involves the cold air intake kit, which typically includes an air filter and an intake elbow. This system ensures that clean air is delivered to the engine while minimizing turbulence.
How It Works:
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The air filter removes contaminants from incoming air.
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The intake elbow directs the filtered air into the engine. A shorter, smoother air path reduces turbulence and ensures more efficient airflow.
A practical example comes from a 6.7 Cummins forum, where a user upgraded their intake system on a 2007.5 DS 6.7L Cummins. The results were striking: boost pressure increased from 9 PSI to 22 PSI. This improvement highlights how smoother airflow translates to better engine performance.
Function of the intercooler and intercooler tube
After the air is pressurized by the turbocharger, it moves to the intercooler for cooling. Cooler air has higher density, which means more oxygen for combustion, resulting in greater power and efficiency.
Why Upgrade the Intercooler?
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Aftermarket intercooler and intercooler tube provide better cooling and ensure stability under high-load conditions.
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Improved air density enables more consistent performance, particularly during towing or hauling heavy loads.
Effect of the intake manifold on airflow
Intake manifolds are an important part of the air intake system, and their task is to distribute air to all cylinders.
If you compare the intake system to a city road network, the intake horn is like a freeway split, distributing the airflow from the main road evenly to the side roads.
If the manifold needs to be better designed, it can act like a traffic jam, resulting in slow airflow.
It is no exaggeration to say that it determines pressure and air flow rate. If you want to minimize pressure loss or increase air flow, replacing the stock intake manifold is a must. Fit for a 6.7 cummins intake horn is worth it!
SPELAB has developed an 6.7 intake horn to fit 2007 to the current generation, which is designed to minimize pressure loss and increase airflow by replacing the material of the OEM manifold and increasing the intake ports by almost two times while designing it to keep the path as smooth as possible.
Learn more about fitting the “6.7 Cummins or 5.9 Cummins intake horn benefits”.
One owner of a SPELAB intake manifold who installed the improved fit for the 6.7 Cummins intake horn noticed an improvement in gas mileage when towing an empty 7x16 trailer for testing.
Fuel consumption on the trailer test improved from 13.1 mpg to 27 mpg, showing how improved airflow can directly impact fuel economy.
The Importance of Intake Plenum Delete
When upgrading the air intake system, consider deleting the factory grid heater. The SPELAB billet aluminum grid heater delete 6.7 Cummins
is a popular choice, offering the following benefits:
Pros:
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Lower intake temperature: Reduced heat buildup improves engine response.
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Better combustion efficiency: Lower intake air temperatures enhance acceleration under high loads.
Cons:
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In extremely hot climates (e.g., Arizona, Texas), removing the grid heater may increase stress on certain components. Consider environmental factors before making this modification.
Increasing air density to optimize combustion
Air density directly affects combustion efficiency. The denser the air entering the cylinder and the higher the oxygen content, the more powerful the combustion process will be.
It's like you're using more concentrated fuel. What can you do to increase air density? Here are some experiences shared by some enthusiastic car enthusiasts:
One trucker with at least 15 years of ownership reported that after replacing the air intake system, the vehicle's performance in cold conditions was significantly more consistent, and it no longer experienced cold-starting problems due to low temperatures.
Another trucker chose to upgrade his intake system to avoid grid heater bolt failures, which resulted in smoother engine starts in cold temperatures and reduced the high cost of engine replacement.
So in order to get higher density, our cold air intake system needs to bring in colder air. This complements the role of the 2 accessories above. It works even better in cold conditions.
Real-world data analysis and linkage to the fuel delivery system
In testing at a pressure of 15 inches of the water column, the SPELAB 6.7L Cummins intake elbow achieved significant airflow gains after the upgrade, which proved to optimize fuel efficiency and engine response.
When modifying intake fittings, it's a good idea to upgrade the fuel lines and high-capacity injectors at the same time. It is the only way to control the balance of the air-fuel ratio better.
Similarly, a modification of the delete system performed by a friend will also be replaced at the same time as the transmission. Otherwise, it will shorten its life due to overloading or other derivative problems.
Conclusion
Upgrading the air intake system for your 6.7L Cummins can significantly enhance engine performance, fuel efficiency, and horsepower. However, it’s crucial to approach modifications holistically, as changes to one component can affect the entire system.
Key Takeaways:
Upgrade the intake manifold: The SPELAB model is an excellent choice for maximizing airflow.
Pair with complementary modifications: Cold air intake systems, intercoolers, and exhaust upgrades work together to optimize engine performance.
Consider environmental factors: Tailor your upgrades to suit your specific driving conditions and climate.
By investing in a high-quality intake system upgrade, you can unlock your Cummins engine’s full potential and enjoy the benefits of increased power, better fuel efficiency, and a smoother driving experience. Take the next step and experience the difference for yourself!
FAQs
Q1: What specific tools do I need to install an upgraded intake manifold?
A1: You will need basic hand tools like a socket set, torque wrench, and screwdrivers. For precise installations, additional tools like a gasket scraper and thread sealant may be required.
Q2: Can an upgraded intake system reduce turbo lag?
A2: Yes, by improving airflow and reducing restrictions, an upgraded intake system can help the turbocharger spool up more quickly, reducing turbo lag.
Q3: Is professional installation necessary for all upgrades?
A3: While some upgrades like cold air intakes can be DIY, complex components like intake manifolds or intercoolers are better installed by professionals to ensure proper fit and performance.
Q4: How long does it take to install a grid heater delete?
A4: Installation time varies but typically takes 2-4 hours depending on your experience and tools available.
Q5: Will these upgrades affect emissions compliance?
A5: Some upgrades, like grid heater deletes, may impact emissions compliance. Always check local regulations before modifying your vehicle.
Q6: What maintenance is required for upgraded air intake components?
A6: Regularly inspect and clean the air filter, and check for debris or wear in the intake elbow and intercooler tubes to maintain optimal performance.
Q7: Can I use an upgraded intake manifold with a stock exhaust system?
A7: Yes, but pairing the upgraded manifold with an aftermarket exhaust system ensures maximum performance gains.
Q8: How does climate affect the performance of an upgraded intake system?
A8: Cold climates enhance the benefits of denser air, while hot climates may require additional cooling solutions like upgraded intercoolers.
Q9: Are SPELAB intake systems compatible with other aftermarket brands?
A9: Yes, SPELAB components are designed to integrate with other popular aftermarket upgrades, but always verify compatibility before purchasing.
Q10: What is the expected lifespan of upgraded intake components?
A10: With proper maintenance, high-quality components like those from SPELAB can last the lifetime of your vehicle.
