Diesel Performance Products Diesel Engine Upgrades Diesel Performance Upgrades Diesel Performance Chip High Quality Performance Parts Diesel Intercooler Diesel Cold Air Intakes Improved Dodge Cummins Performance

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PSM Cold Air Intake 07.5-08 6.7L Dodge Cummins	$109
’07.5 and Newer Dodge/Cummins Cold Air Intake System With the introduction of the Cummins 6.7, getting cold air into the engine is now more important than ever. The additional 50 cubic inches of engine displacement and the mandatory cooled exhaust gas recirculation system located on the passenger side of the engine will no doubt cause underhood temperature to increase more than the 5.9 engine. Our PSM “Cool Power” air intake system provides cold air to the turbocharger while retaining the factory sealed air box and is the only commercially available intake system that is tested and proven to provide cooler air to the turbocharger and engine. Description: With the installation of the “Cool Power” air intake system, additional cold air is delivered to the stock “sealed” air box through a PSM duct located beneath the air box. Cold air is picked up as the air passes under the vehicle. Air enters an inlet port located behind the bumper at the bottom of the stock vertical air baffle (Photo 8). Cold air then flows into the bottom of the stock air box through a 4” diameter duct. An air box flange is attached to the box to secure the duct to the air box. The stock vertical baffle and the existing factory fender side air inlet opening are retained to prevent hot underhood air from entering the air box. Benefits: • Lower EGT: Cooler intake air in more dense which allows the engine to make the same power with less fuel. Less fuel in the combustion chamber will result in lower exhaust gas temperature (EGT). An EGT reduction of 40-50°F is not uncommon when cold intake air is delivered to a “sealed” air box. Since cooler intake air equals lower EGT, more fuel can be injected into the combustion chamber to increase power and still remain below the maximum recommended EGT. • Increase in engine power: Cooler air intake temperature results in an increase in air density and allows your Cummins to make more power when racing, towing heavy trailers or loads up steep grades on hot days. • Lower intake air flow resistance: Increasing the air inlet opening into the stock air box by providing an additional inlet to the bottom of the air box results in lowering the air flow resistance through out the air intake system. This allows the turbocharger to respond to throttle changes quicker, resulting in faster turbocharger spool-up, boost response and increase boost pressure for more power at mid-range and top end. Your air filter minder will now remain in the lowest position at all times. • Insulates intake air from underhood heat: Keeping hot underhood air from entering the air intake system is paramount in making additional power and lowering EGT. Currently, all automotive diesel truck manufacturers use a “sealed” air box where the fresh air inlet to the box is 100% sealed from the engine compartment to ensure that the coldest intake air comes from outside the engine compartment. The only downside in using a sealed air box is that there is limited space to allow air to enter the box, which causes additional air flow resistance. PSM corrects this problem by creating another inlet opening at the bottom of the box. Keeping the air cool once inside the air intake system is also important. It is a fact that plastic air boxes conduct heat 20 times slower than a steel air box. PSM believes there is no better air box available than the factory plastic “sealed” box. • Faster engine cool down: PSM intake system uses air from outside the engine compartment, which results in lower underhood temperatures and faster engine cool down prior to shutting down an engine compared to any other aftermarket air intake system. • Factory appearance: Retains the stock air box and sensors in their stock location to provide that unmodified “look” which does not raise suspicion or jeopardize the factory warranty. • Corrosion resistance: Our intake system components are constructed from non-corrosive materials using rubber, plastic and stainless steel that will not rust or turn color. • Engineered to Perform: PSM is known for thoroughly testing their products for performance, durability and reliability. Whether it is on the dynamometer or in real-world testing under all climatic conditions, our products are proven to perform. We offer a money back guarantee if our air intake systems does not provide more cold air to the turbocharger than any other aftermarket intake system. Specifications: • PSM exclusive bellmouth designed air Intake Port and Air Box Flange are manufactured from ABS thermoplastic material. • Duct is 4” Ø I.D., manufactured from a thermoplastic/rubber compound and reinforced with fabric and a spiral wound steel wire. Duct is rated at 27 psi positive pressure and 2 psi negative pressure with a maximum 325°F operating temperature. • Stainless steel hose clamps. • Cadmium plated fasteners. • 70 Durometer SBR fabric reinforced washers. Installation: Installing the flange to the air box will require a 3-⅝-inch diameter hole to be cut into the bottom of the box. A template is provided to locate and to scribe a circle on the bottom of the air box. Cutting the hole can be performed using a keyhole saws, saber saw, Dremel-type tool or a hole saw. The same template is used to locate the flange on the box while (4) ¼” Ø holes are drilled through the air box. Removing and re-installing the air box with the intake duct attached is done using common automotive hand tools. Our cold air kit come complete with air box flange, flange template, duct, inlet port, hose clamps, fasteners and detailed instructions with pictures. [ More Information ]

Cold Air Intake System for 2nd Gen. Dodge Trucks	$109
Numerous requests for a true functional cold air intake system for ’94-’02 Dodge/Cummins pickup trucks prompted Performance Systems Manufacturing (PSM) to develop, test and perfect their “Cool Power” Cold Air Intake System. Owners of 2nd generation trucks that use power tuners and plates have a difficult time in controlling high EGTs when racing, towing large trailers and carrying loads. Hot air given off from the turbocharger and exhaust manifold easily enters most aftermarket air boxes, raising EGTs and lowering engine power. Our product solves this problem. PSM has used proven technology gained from their 3rd generation Dodge/Cummins cold air intake kits to reduce the high EGT problem by retaining the factory “sealed” air box and by supplementing additional cold air through a custom engineered duct located between the air box and firewall to capture high pressure air from the cowl. Cowl air intake induction has been successfully used on race cars since mid-60s with cowl induction hoods and intake ducts that obtain high pressure air from the base of the windshield. This high pressure cold air is actually forced through the PSM cowl duct to pressurize the stock intake system, reducing air flow resistance by 25% in the stock air box and increasing turbocharger spool-up and boost for more torque and horsepower. Your air box filter minders will now stay out of the “red zone”. In addition to an increase in power, the greatest benefit from the PSM cowl duct comes from reducing air intake temperatures. Our real-world testing has shown that the cold air obtained from the cowl area will decrease the overall air intake temperature at the turbocharger by 7-9 degrees when compared to using the factory single inlet opening in the stock air box. When comparing the PSM cowl air intake duct performance to most aftermarket “Shield type” air boxes, the air intake temperatures difference is 40 degrees and greater. Lower air intake temperatures results in lower EGTs, lower under hood temperatures and increase in air density which permits your Cummins to make more power especially when racing, towing heavy trailers or loads up steep hills on hot days. PSM cowl air intake duct is manufactured from high quality silicone rubber, reinforce with 5 layers of fabric and a spirally wound stainless steel wire to add stiffness and resistance to air pressure. The duct is available in blue or black. This kit comes complete with detailed instructions, pictures and templates to make the required holes in the air box and firewall. [ More Information ]

TECHNICAL INFORMATION

We all have heard of the phases “an engine is essentially a giant air pump” and "more air in and more air out equals more horsepower”. What is not clearly understood is that there is a limit to how much air an engine can digest. We can’t force more air into an engine, no matter how big the air intake system is, if the engine does not want it. Engine air requirements are determined by the following: engine size (displacement), RPM at maximum horsepower, maximum boost pressure, and engine volumetric efficiency. The graph below shows the air flow needs for our 5.9 Cummins.

The above graph assumes a typical volumetric efficiency (VE) for the stock Cummins engine. Changes to a better air intake system, larger intercooler, camshaft and turbocharger or ported head will improve the VE up to 10% above the CFM values shown. A stock '04 Cummins engine is set at the factory at 22 psi boost with the maximum horsepower occurring at 2900 rpm. From the above graph, the amount of air needed by this engine is 640 CFM. If the boost is increased or the engine rpm at maximum horsepower is raised, the engine's air requirement will be increased.

The Dodge/Cummins stock air box and air filter is larger than the Duramax and Power Stroke and consequently Dodge has the least restricted stock air inlet system of the Big Three. PSM real-world and dyno testing has shown that the most restricted part of the Dodge air box is the air inlet area into the box. Dodge must have realized this limitation as they increased the inlet area into this box from 19 square inches to 26 during the '04.5 model change. Even this larger area is insufficient to feed the air box all the air the engine requires. We have solve this problem by providing additional air inlet area at the bottom of the stock air box by using a 4-inch diameter duct that provides 12-1/2-square inches more area for increased air flow into the air box. The PSM cold air intake system will provide sufficient quantity of air to the Cummins engine to produce 450 rear wheel horsepower.

The stock air filter is adequately sized for the stock air box. However, our testing has shown if we add additional air to the box using the PSM cold air intake kit, the filter now becomes the limiting factor in delivering all the air the Cummins engine needs for maximum performance. A small gain in performance can be obtained by changing the stock air filter to a high performance filter.

To maintain the maximum performance from the engine, the density of the air entering the air intake system is very important. PSM real-world testing showed that horsepower gains from most aftermarket air intake systems that increased air intake flow can be totally negated if underhood air heated by the engine is getting into the air box. In fact, when this situation occurs, our testing has shown the engine will produce less horsepower than an engine using the stock unmodified air box. Most aftermarket air intake manufactures appear not to understand nor consider the total effects of underhood heated engine air getting into their air boxes. Most aftermarket air boxes are designed to shield hot air from the air box, but does not prevent hot air from entering the air box. Our testing has shown that the stock Dodge “sealed” air box design is the best air box for preventing hot underhood heat from entering the air intake tube. The following graph shows these temperatures during a 4-mile 6% grade climb.

From the graph you can see that underhood air can exceed 150 degrees. The air intake temperature for the "shield" type air box follows the rise and fall of the underhood air temperature because a "shield" air box obtains 45-50% of the air from under the hood. The stock air box is "sealed" and obtains air between the inner and outer right front fender where the air is much cooler and isolated from the heated underhood air. The PSM cold air intake kit provides additional cold air from behind and below the front bumper to the stock air box thus lowering the intake air temperature an average of 2.5 degrees below the stock system or 32 to 44 degrees below a typical "shield" type air box.

When using a "shield" type air box, underhood air temperature is self-perpetuating; hot underhood air results in hotter intake air, resulting in higher EGTs, causing underhood air temperature to increase, resulting in this cycle being repeated until you back off on the throttle as shown the 3.5 mile point on the graph.

Why is keeping hot air out of the air intake system so important? Air is made up of molecules. Molecules that get hot expand and become larger than cool air molecules. Fewer hot air molecules can be packed into a given volume (say a 1-foot cube) compared to the number of smaller cool air molecules. The greater number of air molecules that can be placed in 1-cubic foot box, the heavier the box becomes. The heavier the box is, the denser the air is inside that box. The more air molecules the engine digests in a cubic foot of air the more power an engine will make. Therefore, to maximize the power of your engine, you should use an air intake system that provides cold air to the engine under all driving conditions. Engines typically produce 5% more horsepower for every 30 degrees of cooler intake air. A PSM cold air intake system is one of the very few systems available that can deliver a continuous supply of cold air to the engine for maximum performance.

With the Electronic Control Module (ECM) in our ‘03 and newer common-rail trucks, fueling adjustments are continuously made while the engine is running. There are two sensors (1 on the engine which is called the manifold absolute pressure (MAP) and the other on the air intake duct) that measures air temperature and air pressure. The MAP sensor sends continuous data to the ECM which calculates air density and makes adjustments to the fuel injector flow. When air intake temperature is increasing, the MAP sensor sends a signal to the ECM which in turns reduces the time the fuel injectors are turned on. This reduces the amount of fuel injected into the combustion chamber. Less fuel injected means less power is being produced. The exhaust gas temperatures will also go down since the heat produced during combustion is less.

To summarize, air flow and air density have major influence in the overall performance of an engine. Aftermarket published air flow numbers that are greater than the engine’s requirements do not produce additional horsepower. Providing cold air to the engine under all driving conditions will guarantee the maximum horsepower and torque from your diesel engine. PSM has performed the dyno and real-world testing and strongly believes they have designed the best and lowest cost cold air intake system for the ‘03 and newer Dodge/Cummins turbo diesel trucks for heavy towing and hauling applications.

BENEFITS OF PSM COLD AIR INTAKE SYSTEM

The benefits listed below were obtained from "real-world" driving observations and instrument monitoring of EGT, air intake, underhood air, and ambient air temperatures, during towing a loaded 9,500 pound trailer and from dynamometer testing the truck over a 1 year research and development period. Tests were run from 6,000 to 11,000 feet elevation, from 20 to 95 degrees temperatures. These benefits are:

+Retains the sealed factory stock air box, intake tube and sensor in the stock location for the unmodified stock look, yet provides better performance in hot weather than other aftermarket intake systems.

+Engine and drivetrain factory warranty is not jeopardized and the kit is not visible from the engine compartment.

+Our air inlet port is located furthest from the engine compartment to eliminate underhood engine heat from entering the intake system and causing engine de-fueling and loss of power from less dense air. Inlet port is close to the front bumper for maximum exposure to the cold air in front of and under the vehicle.

+Air baffle is used as a secondary means to prevent underhood engine heat from entering the intake system.

+Our air intake system uses no metal components that may rust or transfer heat into the intake system like many other aftermarket metal air boxes or tubes.

+An economical cold air intake system for stock or modified single turbocharged Cummins engines with sufficient air flow for up to 450 horsepower.

+Engineered to provide maximum air density to the engine at all times, under all driving conditions, including heavy towing up steep grades for extended periods of time.

+Dyno and real-world acceleration tested to provide faster turbo spool up resulting in 15-20 horsepower and 35-60 ft-lbs torque increase between 1800-2500 RPM. Increases peak power 7-9 horsepower and 14-18 ft-lbs torque at 2800 RPM.

+Lowers EGTs by 40 degrees or more while heavy hauling and towing due to the cooler intake air entering the combustion chamber.

+Average 16 degrees lower EGTs during idle cool down than aftermarket "shield" type air box designs that take in hot underhood air.

+Tested and proven to work in harsh weather including heavy rains, sleet, slush, ice and snow.

+Theoretical improvement in fuel mileage although actual observed improvements will not be detectable. (However, some customers still report mileage improvements when climbing hills or mountains)

FREQUENTLY ASKED QUESTIONS

How difficult is the installation? The installation instructions are clearly written in a step-by-step format with many color pictures. Installation should take about 45 minutes. You will need some metric and standard sockets, a flat blade screw driver, medium size clamp, saber or keyhole saw, safety razor blade, drill with ¼" Ø bit and a marking pen. The most time consuming part is cutting a hole in the bottom of the stock air box. The '03 - '04 kit with fog lights will require drilling (2) ¼" Ø holes in the bottom of the air dam and 1 hole in the plastic inner wheel well.
Can rain and snow get in the inlet duct and air box? Rain and snow is much heavier than air. With the small negative pressure (2-3" of water column pressure or about 1/10 of one psi) created when the engine is operating at full throttle, water and snow will continue horizontally past the air inlet port and not be drawn into the air box. Our testing has proved this to be the case in heavy rains, ice, sleet and snow driving conditions. On the Buick Grand Nationals our air filter is located only 10" above the road surface and protected by the front bumper air dam. No adverse effects from rain or snow have occurred with over 500 kits on the road during the past 8 years.
I live on a dirt road, will the PSM air intake kit allow more dust to enter the air box? The air inlet port is 12-15-inches above the road surface and will not "suck up" dust off the road. The inlet port is also forward of the front tire and the dust created by the front tire will be behind the tire. Real-world testing on dirt roads was performed by TDR member John Holmes who lives on his Nevada ranch, 2 miles off the paved road. He reports that his air filter is not any dirtier with the cold air kit installed. John does recommend that one not closely follow any vehicle on a dirt road with or without this kit.
Can I go 4-wheeling with the PSM air intake kit? This air intake kit is supplemental to the stock air box inlet. If one was to ford a 3 foot depth of water, the stock located air box inlet would still supply air to the engine while the PSM inlet port is under water. Water must submerse the air box before damage to the engine would result.
How much will the PSM intake kit lower the air inlet temperature? During our real-world testing under extreme towing conditions we found underhood air temperatures as high as 150° F. while traveling at 60 mph up a 6 - 7% grade. Our intake kit using the "sealed" stock air box showed a maximum 5 - 6 ° F. rise in air intake temperature above ambient temperature during this test. When testing aftermarket "shield" type air boxes, intake air temperature rise was observed at 47 ° F. above ambient. The 41 ° F. lower air intake temperature from the PSM intake system results in increased air density, producing 7% more horsepower and torque while pulling upgrade.
Will cold air intake kit increase my fuel mileage? Theoretical "Rule-of Thumb", is for every 10° F. cooler intake air, the fuel mileage increases by 1%. This is a very minimal increase when our trucks only get 10 - 13 mpg while towing. Any increase will not be detectable as there are much larger factors that affect fuel mileage, like terrain or wind.
I have a "shield" type air box system on my truck. What improvements will I see if I change to a PSM cold air intake? The difference between the "shield" air box and the PSM system will be noticed during heavy engine loading and towing up steep grades. That is where the PSM system will out perform the "shield" type air box with lower EGT's, more horsepower and torque and faster acceleration. This performance is possible because the PSM system is taking in denser air from the cold air inlet behind the front bumper. Faster reduction in EGT's during engine cool down is also obtain with the PSM system compared to a "shield" type air box.