Boosting Performance Expert Tips on How to Get the Most Bang for Your Buck
Written by Joe Pettitt Photos by Joe Pettit & Courtesy of the Manufacturers
Page 1 of 3
When it comes to turning up the wick on your turbo diesel-powered truck, it usually comes down to installing the right combination of power parts. Basically, pumping up the power on a diesel engine requires moving more air and more fuel through the engine.
The first order of business is to get more air mass into the engine in order to add more fuel to burn with the added oxygen, which in turn generates higher cylinder temperatures and pressures associated with higher engine power output. Fortunately, aftermarket support for today's turbo-diesel engines makes making power almost too easy with super efficient air filters, intakes, and exhaust, intercoolers, programmers, fuel pumps, injectors, and turbos. It's all out there. All it takes is money and knowing what to choose, when to install and how to tune it.
In this article we'll focus on the "what to choose and when to install it" of teasing more power from your engine. The original premise for this article was to delve into when you should step up and install a more "powerful" turbo, i.e. a turbocharger with more mass flow. However, upon interviewing several leading figures of the performance diesel community, it quickly became clear that for most enthusiasts, installing a high-flow turbo wouldn't be to their benefit. Not that tweaking the turbo a bit wouldn't be advantageous on some makes and model years of diesel trucks. However, everyone was in agreement that there is a proper sequence of installing performance equipment, and that larger turbos were only a small piece of the puzzle.
We posed a series of questions about the proper sequence of upgrading a turbo diesel to Petery Treydte, Director of Technical Communications at Gale Banks Engineering; Justin McCarthy, Technical Manager, Bully Dog Technologies; Brian Roth of BD Power, and Max Lagod, owner, Hypermax Engineering.
You'll notice for the most part the industry is in agreement on the overall approach. However, there are some divergent opinions on the order of operation and in the area of modifying turbochargers. We're not here to settle those differences. We're of the opinion that the sources we consulted are knowledgeable and credible. The differing views probably arise from each firm's experience with various combinations and approaches. We suggest you shop intelligently and ask a lot of questions of each source before you buy. In the meantime, here are their comments:
What is the most cost and performance effective sequence of adding performance components?
A:Diesel upgrades have become a very personalized arena and everybody has an opinion about the best methods and products to use to improve the performance of their vehicle. There are many issues that can affect an individual's choices regarding the order in which modifications should be done, including: budget, performance improvement, impact on fuel economy, and even the make of the vehicle.
Generally speaking, a Ram-Air intake is a good first modification to make because it is relatively low cost, is easy to install and will give a moderate improvement in fuel economy and power. Improving airflow into the engine is logically followed by a free-flowing Monster Exhaust to allow the air out of the engine.
After these two modifications, a Six-Gun tuner is the next logical step; increases in airflow mean that fuel can now be safely added to the engine for dramatic power increases. Those who are serious about achieving the maximum potential from their engine should next consider an intercooler upgrade for increased air density.
Turbocharger, injector and fuel pump upgrades should only be considered by serious racers and will be the most costly upgrades. These types of modifications will require customized fuel tuning for optimum results. - Peter Treydte, Gale Banks Engineering
A: My order of preference is electronics, intake, exhaust, injectors, fuel pump, then intercooler. Combinations producing less than 600 hp generally do not need an intercooler upgrade and turbo upgrades are usually not needed at power levels below 500 hp. Electronics, intakes, and exhausts are the most cost effective parts for your daily driven truck. If you want to build a truck for sled pulling or drag racing, then you'll need to upgrade injectors, turbo, fuel pump, as well as adding a heavy duty transmission, larger head bolts, Propane or water methanol. After those components are installed and tuned, you could add the intercooler. - Justin McCarthy, Bully Dog Technologies
A: I tell my customers the first 100 hp is relatively inexpensive; it's the second 100 hp that costs real money. We have a good reliable package for the 6.0-liter engine. We've got an exhaust, an electronic module and a bigger intercooler for the Fords. That puts them in the range of 485 hp. The next phase is to enhance reliability. The Fords don't have the best track record for head gaskets. So we have performance head gasket sets. Next is stepping up on the injectors and a turbo upgrade then you have a package that's reliable while making power above the 500 hp level.
With our Mach7 package, we're making about 480 to 500 horse. Some guys have trouble with the head gaskets, some don't, but that's the threshold or limit of what the stock components can contain. But for the guys who add 100 hp and are now making 425 horse, they tend to keep chugging along. But they don't stay there. They end up turning the daily driver into a hot rod truck.
NewCummins Kit - Ball bearing turbo upgrade kit from garrett for Dodge Ram 2500 and 3500 2002.5-2004 and 2004.5-2006 model years with Cummins 5.9L Turbo Diesel Engines. www.TurboByGarrett.com
Engineered by BD and built to our exacting specifications by BorgWarner Turbo Systems' AirWerks program, the Super Max creates enough airflow for up to 550 rwhp at 45 pounds of boost on diesel only (up to 675 rwhp with a shot of nitrous!). Increased efficiency reduces exhaust gas temperature (EGT), lowers emissions and even improves fuel economy over the stock turbo.
Super B Single from BD Power. Designed for '94-06 applications, the Super B Single supports modified applications making up to 425 rwhp. The Super B single offers quick spool-up, cooler EGTs and no surging. It's ideal for street, towing and mild competition applications, and can easily be upgraded to a twin system for even more power.
BD Power's Super B Special bridges the performance gap between the Super B turbo and the Super B twin system. Flowing 80 lbs. of air per minute compared to 61 lbs./minute for the Super B, the Super B Special is designed for late-model Cummins common-rail or modified 12-valve engines and can deliver enough air for 550-625 rwhp on diesel only. A bolt-in replacement for the stock turbo, the Super B Special kit includes all necessary adapters, new down pipe, spring-loaded T-bar clamps and turbo feed/drain fittings.
BD Performance's Stock and performance Ford 6.0 Diesel replacement turbocharger is engineered to flow air for 550 hp. It offers quick turbo response, low exhaust temperatures, and better fuel economy. www.BD-Power.com
Bully Dog has a line of free flowing intakes for most popular makes and models.
Banks Ram-Air Intake System is flow-bench developed, dyno proven. They claim it improves airflow 44 percent, Design features includes enclosed cold-air box and huge 7-1/8-inch outlet.
The BD Xintake Stainless Steel Air Intake is designed to allow for maximum airflow through the intake for quicker throttle response, lower exhaust temperature and increased power output. If your engine breaths better it will perform better. BD's polished, stainless steel intake box looks and works great combined with a performance free-flowing air filter.
Banks Power High-Ram Cummins powered Dodge Ram, improves airflow from the intercooler. High-Ram raises boost without increasing backpressure at the turbine. Result: a more responsive, fuel-efficient engine.
