Top Ways to Maintain Your Truck’s Fuel Efficiency (Complete Guide)

As fuel prices swing up and down, everyone wants to stretch every tank further—especially truck owners who daily drive, tow, or spend long hours on the highway. The good news: you can often pick up meaningful MPG by fixing small problems that quietly waste fuel (leaks, restrictions, worn components) and by optimizing how the truck moves through air and down the road.

Start Here: Baseline Checks That Restore Lost MPG

Before buying parts, confirm you’re not losing fuel economy to something simple. These “baseline” items often restore MPG immediately:

• Check for boost leaks: Leaks in the charge air system can increase smoke and EGT, and force the turbo to work harder.
• Replace clogged filters: Dirty air and fuel filters can reduce efficiency and power.
• Confirm tire pressure + alignment: Low pressure and toe misalignment can eat MPG fast.
• Fix exhaust leaks: Leaks before sensors/turbos can affect performance, spool, and heat management.
• Scan for codes: Underboost, sensor faults, or regen-related issues can quietly drain MPG.

1) Check and Upgrade Your Manifolds

If your manifolds are leaking, warped, or failing, you can lose energy that should be driving the turbo and building boost. That can lead to slower spool, higher EGT under load, and more throttle to do the same work—meaning more fuel used.

Signs of manifold trouble: soot near the manifold, ticking under load, exhaust smell in the engine bay, slower spool, higher-than-normal EGT when towing.

BD Diesel manifolds are made from high-silicon ductile iron to handle heat cycles without cracking. Their flow-focused design can help improve thermal efficiency and spool, which often supports better real-world economy—especially on trucks that tow. See BD’s manifolds here.

2) Check, Service, and Upgrade or Replace Your Fuel Injectors

Injectors are a precision device. When they’re worn, dirty, or not atomizing correctly, you can get incomplete combustion— which means less power per drop of fuel.

Common signs of injector issues: rough idle, haze or white smoke, harder starts, increased consumption, louder combustion knock, or uneven cylinder contribution.

BD Diesel injectors are shot-to-shot tested and built to a higher standard than OEM to deliver consistent fueling and value.

3) Replace a Worn Turbo or Failed VGT Actuator

A healthy turbo supports efficiency because it helps the engine breathe—especially under load. But when a turbo is worn (excessive shaft play, damaged compressor/turbine, sticky vanes) or when the VGT actuator fails, you can end up with poor boost control. That typically means more throttle, more smoke, and higher EGT for the same task.

BD’s Screamer turbos are built in-house, high-speed VSR balanced, and offered for Power Stroke, Cummins, and Duramax applications. A properly matched turbo can provide a cooler, denser charge and support cleaner combustion—key ingredients for better fuel economy.

4) Install a TSBooster With Eco Mode (Smarter Throttle, Smarter MPG)

The right driving inputs matter. If your truck is responsive, you can often run less pedal for the same result. Eco mode strategies can help reduce aggressive throttle application and keep the engine in a more efficient operating range.

With TSBooster features like adjustable throttle response and security mode, Eco mode can be ideal for daily driving. The goal is smoother inputs and less unnecessary fueling—especially in stop-and-go traffic.

More Ways to Improve Fuel Efficiency (Beyond the Top 4)

5) Fix Boost Leaks and Charge Air Restrictions

Boost leaks waste the work your turbo is doing. They can increase smoke, raise EGT, and make the engine feel lazy—so you push the pedal harder. Pressure testing the system (turbo → intercooler → boots/pipes → intake) is one of the best “bang-for-buck” MPG diagnostics.

6) Keep the Air Filter and Intake Path Clean

A restricted intake can reduce airflow and increase pumping losses. If your truck is used in dusty conditions, check the filter more often. Inspect the intake tube and clamps for cracks and loose connections that can cause unmetered air or poor performance.

7) Maintain Fuel Filters and Watch for Low Rail Pressure Issues

Dirty fuel filters can starve the system, change injection behavior, and reduce efficiency. If you notice harder starts, lower power, or inconsistent performance under load, don’t ignore fuel supply health.

8) Use the Right Oil, and Don’t Ignore Service Intervals

Oil that’s too thick for your climate can increase drag and reduce cold-start efficiency. Sticking to the correct oil spec and interval supports lower friction and better long-term MPG.

9) Tire Pressure, Tire Type, and Alignment Matter More Than Most People Think

Underinflated tires increase rolling resistance. Aggressive mud tires can cost MPG on the highway. Alignment issues (especially toe) can scrub energy constantly. If you do one “free” thing today, check pressures and alignment.

10) Reduce Unnecessary Weight and Drag

Toolboxes, racks, and loaded beds add weight. Roof-mounted accessories and open tailgate airflow can add drag at highway speeds. If you’re chasing MPG, think “less weight, smoother airflow.”

11) Drive for Efficiency: Speed, Throttle, and RPM Strategy

Fuel efficiency often comes down to keeping the engine in its efficient band: smooth throttle, earlier upshifts (where appropriate), steady speeds, and avoiding unnecessary idling. Small changes—like dropping cruising speed a little—can create big gains over long highway trips.

12) Control EGT and Heat (Especially When Towing)

Heat is a tax on efficiency. When EGT climbs, you often add more fuel to maintain speed, and components can protect themselves by changing strategy. Better airflow, sealed boost plumbing, healthy turbo control, and good exhaust flow all help manage heat.

13) Address Sensor Issues and Unnecessary Regens (If Equipped)

Faulty sensors (boost/MAP, EGT, fuel pressure) can cause the truck to run inefficiently. If your truck is doing frequent regens, that fuel has to come from somewhere. Scan, diagnose, and fix the root issue instead of living with it.

Fuel Efficiency While Towing: What Matters Most

Quick Checklist: Do This First

• ✅ Check tire pressure + alignment
• ✅ Replace dirty air + fuel filters
• ✅ Pressure test for boost leaks
• ✅ Inspect for exhaust leaks/soot at manifolds
• ✅ Scan for codes (underboost, sensor, regen-related)
• ✅ Verify turbo/VGT actuator health if spool feels slow

FAQ: Truck Fuel Efficiency

Can an exhaust manifold leak hurt fuel economy?

Yes. Leaks can reduce exhaust energy reaching the turbo, slow spool, raise EGT under load, and make you use more throttle to do the same work.

Do injectors affect MPG even if the truck still “runs fine”?

They can. Poor atomization or imbalance can reduce combustion efficiency, increase haze/smoke, and require more pedal for the same power.

Will a bigger turbo increase fuel economy?

Only when it’s properly matched to the truck’s fueling, tuning, and use-case. The wrong turbo can hurt response and efficiency.

What’s the fastest way to regain lost MPG?

Baseline maintenance and diagnostics: tire pressure/alignment, filters, boost leak testing, and fixing exhaust leaks.

Although fuel prices are out of your control, there are practical steps you can take to make your truck more efficient and minimize the impact on your wallet. For more information on BD Diesel products mentioned here, visit us.bddiesel.com.