A Letter from Dan Montegari - President
of Precision Diesel Services
We received many letters asking which high flow air intake
systems to use. We decided to test a number of manufacturers' systems
to determine which system was superior. We tested each system and
found systems manufactured by aFe (Advanced Flow Engineering) were the
BEST by far.
Diesel engines use seven times more air than gasoline engines of
equivalent size so clean cool air is a must for extended engine life,
better fuel economy, and additional power. A higher flow of intake
air coupled with a high flow exhaust system allows for more power, a
better fuel economy, extended engine life and reduced exhaust
temperatures. On the other hand ingested dirt through the air intake
system becomes Silicon in the engine oil, which is a harsh cutting
agent and can damage your engine quickly.
We tested three very popular systems. I will not mention the
names of the other systems as a courtesy, but I will explain what
problems we found with them. We evaluated the systems by a number of
criteria, filtration protection, flow, design, ease of installation,
and cost. Almost in the beginning of the tests we realized in most
instances a new intake system was necessary to achieve our goals. We
needed a kit that used mostly outside air and not hot engine
compartment air. We decided to use systems designed to use mostly
outside air.
Two manufacturers claimed their systems delivered cleaner air at
a higher flow, but this was far from the truth. We did not believe
any of the manufacturers' claims and tested each system by operating
the vehicle 3,000 miles and performing an engine oil analysis
performed at every oil change so they had a Silicon number of three
(3) to base their tests on.
The first manufacturer's system was fairly easy to install but we
had problems with the oil used to coat the filter also coated the Mass
Air Flow Sensor causing a service engine lamp to come on. I called
the manufacturer but they had no explanation as to why this should
happen but they had this complaint before. Through the three thousand
mile test I had to clean the sensor three times to stop the service
engine lamp from coming on. When the oil analysis results came back,
is was discouraging with Silicon levels at eleven (11). I almost
could not believe the result, so we changed the oil and filter and
repeated the test. The results were almost the same eliminating this
manufacturer quickly. I contacted the manufacturer to discuss the
results and they were not helpful and basically said, "what you see is
what you get"!
We installed the second manufacturer's system again changing the
engine oil and operating the vehicle for three thousand miles. The
first problem we encountered was the service engine lamp coming on and
I thought the oil they used was coating the sensor again. I removed
the sensor and found some oil on it which I cleaned off and
reinstalled the sensor. Within ten miles the lamp was on again. I
removed the sensor but there was no coating of oil on it. I then
placed our scan tool on the engine and quickly discovered the airflow
rate was too high for the sensor. I then realized the manufacturer
had moved the position of the sensor into a higher airflow and
velocity position trying to squeak a little more power from their
system. I continued the test having to deal with the service engine
lamp throughout the test period. The engine oil analysis gave a
Silicon reading of eight (8) and along with the engine lamp problem
did not give the manufacturer high mark but I felt if I discussed the
problems with them, maybe we could overcome them. I placed four calls
to the manufacturer and I am still waiting for a call back! This
surely eliminated this manufacturer.
The third manufacturer we tested was aFe (Advanced Flow
Engineering). We used their Magnum Force air intake system. We
operated the vehicle for 3000 miles and when the oil analysis came
back it was promising with a Silicon reading of five (5). While five
was the best Silicon result we had, it was not good enough. I called
aFe and was pleasantly surprised when I discovered they were truly
concerned. I spoke with a Mr. Paul Hardley who suggested I try their
Pro-GUARD 7 media they were about to release. He explained the new
Pro-GUARD 7 media was five layers of progressively woven synthetic
polyester fabric with random porosity. The filter media is sandwiched
between two layers of aluminum wire mesh. He agreed to send two
Pro-GUARD filters for a new test. I installed the Pro-GUARD 7 filter,
changed the engine oil and operated the vehicle for three thousand
miles. The engine oil analysis was excellent with a Silicon reading
of below three (3). Finally we found an air intake system that gave
us a higher flow rate and better filtration. The aFe Magnum Force air
intake system is a well-designed system, easily installed and uses
about 90% outside air. The filter is cleanable and the oil used to
coat the filter is patented because it is formulated not to affect
the airflow sensor.
Another positive factor of the high flow system was the fuel
economy increased about 1/2 MPG in mixed driving and 1 MPG during
highway tests. The filter media used by aFe will not collapse if it
gets wet of subjected to high boost pressures. They also offer
pre-filters for most of their applications for very dusty or dirty
operating conditions.
A very important factor in this test was the manufacturer was
willing to discuss problems with their products and help to overcome
them. My hat is off to Paul Hardley and all the people at aFe.
Dan Montegari
President
Precision Diesel Services, Inc.
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