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If you block the intercooler your EGR Valve might not open as much, I think the fuel economy is from the EGR being closed earlier due to faster warm up. On my Ford 6.0L I feel that the EGR valve causes terrible fuel milage on warm up.
Also I find that Diesel tend to be much more efficient on accelaration then Gas Engines.
I have a 6 Spd Standard and a ScangaugeII, I found that the the RPM for shifting is from 2000-2250 and I drive at 1750 RPM 55MPH for best Milage. I never use O-Drive in the city because I shift to O-Drive at 45-50MPH. My Scan Gauge indicates lower Milage when I lug the gears at 1200-1400 RPM. So there is no one beeping to pass me in town I usualy I'm the one slowing down for others. I do slow down using the Highest gear due to engine going to 0 L/100. With a 10000 Lbs 5Th Wheel I do 20L/100 and drive 55-60 MPH. Empty I do 12L/100 Combined. So the translation I use is 282/20 = 14.1 MPimpG and 282/12 = 23.5 MPimpG for americans its 235/20 = 11.75 MPusG and 235/12 = 19.6 MPusG Ford test these trucks at 17 MPusG for fuel complaints.
Enough Info but most of my driving is done while trying to keep the scangaugeII indicator at 10-12 L/100 normal, and at 18-20 L/100 with the trailer.
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