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4 M/R Series Cold Air Intake

587 Views 12 Replies 7 Participants Last post by  isukennedy
Thought process is that there is radiator and hydraulic coolers contributing to hot air being sucked into the intake and coming up with something that will draw air from the front would aid the charge air cooler and possibly making its efficiency better in the end.

NOTE: If you are interested in performance gains, well I cannot help you there as I did not dyno a before and after. I'll leave the performance discussions to experts like Gale Banks.

I've been doing a two-part R&D project using the tractor plus app as the validation tool. What I was seeing in the app was that ambient temperature was greater than 30+ degrees F above actual ambient in stock trim, for example in 15F temps my intake temps were around 70-75F. Note the ambient temperature sensor is actually located at the turbo inlet so it is not an actual ambient temperature sensor but rather a turbo inlet temperature.

Part 1 was using some heat wrap material for the air filter housing and hoses to the filter and turbo. This yielded less than expected results and I only saw a decrease in temperatures that were at max 5F lower than what was reported without the heat wrap. So, this to me was a non-starter as the benefit to gain was too low.

Part 2 was working with an engineer friend of mine to develop and test a 3D printed ABA/ABS adapter that would allow for intake air to be drawn in from in front of the radiator and coolers rather than from directly over the top of them and be strong enough with higher heat resistance. Quite the process to keep the inside diameter volume while making the required bends and curves to get around everything. In the end, this was the most significant reduction in temperatures. In testing so far, the difference between ambient and turbo inlet is now only 15-17 degrees F vs the 30+ degrees in stock form.

Due to the location of the inlet, it is very difficult to use fasteners to secure this so a double-sided tape, hot glue, or a light silicone would be the best to mount it. I made a cardboard template of the base and hole so I could mark the radiator shroud and aid in aligning the adapter as aligning the holes would be blind otherwise. I also just used a hose from Amazon to extend to the grill area. Amazon Hose . From what I can see on JD Parts all 4R/M series share the same fan shroud so the intake port should be identical.

Does anyone have interest in something like this for their 4 series? @isukennedy would make these for anyone for $35 shipped to you if you are interested.

Attached is a picture of the final prototype.
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Very interesting. I’m gonna have to look at my 2038R but I think it does draw air from the front screen area.
I'm happy to consider other models and configurations, as well. @pcabe5 and I went thru 3 versions of this before we got it nailed down. My "prototyping fee" is a bottle of bourbon.
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I have a 4066R and would be interested in buying one.
Very interesting, indeed.

Have you done a study of the before/after affect of this modification on Manifold Air Temperature? The Engine Control Unit (ECU) monitors manifold air temperature (parameter ECU-031) which is displayed on your tractor on the ECU diagnostics display.

Ultimately, the end goal would be a reduction in manifold air temperature since this is the air that is directly ingested by the engine.

There is "no free ride" in modifications of this type, and it would be good to know if the negative impacts of adding an intake air restriction and partially blocking the charge air cooler heat exchanger with the large added intake hose are positively contributing to the bottom line where it matters with reduced manifold air temperature.
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@zuress Send me a PM and we'll get something set up. I have some adjustments to make on my printer this week, so it might be a day or two before I'm up and printing.

@JD Driver The temp drop is about 20 degrees when the engine bay is heat-soaked, according to brief testing by @pcabe5 . While the intake adapter does take a strange route around the radiator cap, there aren't any additional restrictions. It maintains the same cross-sectional area as the hole in the firewall throughout it's length. I'm not saying it's perfect, but it's almost certainly going to be better than a corrugated hose.
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Very interesting, indeed.

Have you done a study of the before/after affect of this modification on Manifold Air Temperature? The Engine Control Unit (ECU) monitors manifold air temperature (parameter ECU-031) which is displayed on your tractor on the ECU diagnostics display.

Ultimately, the end goal would be a reduction in manifold air temperature since this is the air that is directly ingested by the engine.

There is "no free ride" in modifications of this type, and it would be good to know if the negative impacts of adding an intake air restriction and partially blocking the charge air cooler heat exchanger with the large added intake hose are positively contributing to the bottom line where it matters with reduced manifold air temperature.
The manifold temperature sensor you are referring to is not a good value. The reason is that sensor is including EGR gases into the equation which the EGR opening percentage is variable, so it would be near impossible to get an accurate reading due to the variability of the EGR valve. You would need a separate sensor on the CAC output to see the air temperature input. In the end there should be a realized reduction in manifold temperature as the air temperature going into the turbo is reduced with everything else staying the same.

There is no intake restriction as the diameter of the adapter and hose is the same as the existing opening of the firewall. Blocking the CAC? The hose will have little to no effect on temp as there is no direct flow this hose would block as the grill in that area is already blocked off across the top and the hose does not rest against the CAC. IMO there would have to be a delta difference between the stock and modified manifold temperature if the start temperature is different and no other changes in the system were created.

Keep in mind the stock intake is behind the radiator and actually partially below the top of the radiator so it will draw in air from the top of the radiator, hydraulic cooler, plus the condenser. This adapter routes the intake above the radiator and around the radiator cap (so it can be removed) and it also slopes down so the hood will clear it. Multiple x/y/z axis movements on the part to make it fit in that location without reducing overall diameter.
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While the intake adapter does take a strange route around the radiator cap, there aren't any additional restrictions. It maintains the same cross-sectional area as the hole in the firewall throughout it's length.
There is no intake restriction as the diameter of the adapter and hose is the same as the existing opening of the firewall.
Sorry, but it just wishful thinking to state that the intake restriction (pressure drop across intake piping) does not increase with pipe length, even when the pipe diameter remains the same.

As shown in this equation, as the pipe length (L) increases, even while maintaining a constant pipe diameter (D), the pressure drop (resistance) will also increase with increasing pipe length.

Creating an intake pressure drop reduces intake air pressure (and air density), which is to some degree counterproductive.

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Are we letting perfect (zero pressure drop) be the enemy of good (reduced intake temps) here?
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Sorry, but it just wishful thinking to state that the intake restriction (pressure drop across intake piping) does not increase with pipe length, even when the pipe diameter remains the same.

As shown in this equation, as the pipe length (L) increases, even while maintaining a constant pipe diameter (D), the pressure drop (resistance) will also increase with increasing pipe length.

Creating an intake pressure drop reduces intake air pressure (and air density), which is to some degree counterproductive.

View attachment 903273
This equation even suggest that cross section should be smaller when length increases to maintain Bernoulli principle. Intake pressure is important for NA engines but when turbocharger is used I believe it is much less important.

Are we letting perfect (zero pressure drop) be the enemy of good (reduced intake temps) here?
It would be really interesting to see some measured effect of this mod. If you do not have access to PTO dyno I would suggest cruder method. Find some constant engine load e.g. pulling a heavy trailer, soil engaging work and monitor engine load in the tractorplus app. I would be really interested if this temperature drop has any real effect. I would definitely remove it during winter months though.
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4
Here are some more photos of the one I just printed for @zuress
The next spool of ASA will be green. I don't know if it'll be a perfect match for JD green, but it'll be under a hood anyway.




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