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
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Realistically, a 6.0-liter, with a electronics package, turbo upgrade, injectors, air cooler and exhaust, can make 625 hp. But then you need to get a transmission that'll handle that. - Max Lagod, HyperMax Technologies
A: The best route to go when adding performance is to start with base components that will help to support the upgraded power. This would mean that a good course of action might be: 1. Exhaust system; 2. Intake kit; 3. Turbo kit; 4. Intercooler; 5. Fuel system upgrade; 6. Electronic tuner/module ; 7. Fuel Injectors.
Having too much fuel or too much power without the supporting pieces makes for unusable performance, not to mention blown-up stock parts.¬- Matt Bozarth, ATS Diesel
A: As with a gasoline performance engine, the best first steps are the simple ones that lay the foundation for getting more air/fuel into the engine, and more exhaust out. We recommend starting off with our X-Intake cold air intake package, and one of our X-Hale performance exhaust systems. The next popular step is to add a performance module, like our X-Tuner for the Dodge-Cummins or Ford Power Stroke, and our Intimidator module for the Duramax. Once you start changing the stock fuel curve, we highly recommend the use of a monitoring system, such as our X-Monitor or new X2 monitor.-Brian Roth, BD Power
Does make and model year influence the sequence?
A: The order of modification upgrades may vary slightly depending on the year and make of the vehicle, but the general guidelines will be predominately accurate. For instance, the factory intercooler on a 1998-2002 Dodge is a relatively good design from the factory and upgrading it may not be cost effective except for the most extreme racers. - Peter Treydte, Gale Banks Engineering
A: Some of the older models you cannot add engine electronics to, other than that the sequence above would stay the same. - Justin McCarthy, Bully Dog Technologies
A: All of the 6.0-liter Fords are the same. I tell my customers if you've installed a chip and you start bumping the power up, you should at least put a pyrometer in the truck to keep track of the exhaust temps, which are the number one killer of these engines. If you don't do anything else, at least you can see that towing that trailer with your foot to the floor is causing the exhaust to heat way up.
I've been keeping our customers with the Mach 7 module in the range of 1200-1300°F by defueling at 1300°. That seems to be the magic number to keep the exhaust valves, pistons and turbochargers alive. Above that, the turbos start glowing and eventually pieces start coming of them and out the tailpipe. Even with the older 6.9 and 7.3 IDI engines, we put the limit at 1250°F and they'd tow all day.
The older IDI engines are all mechanical upgrades. We sell turbo kits, to get the air to the engine. And then we add fuel by turning the right screws on the mechanical fuel pump. - Max Lagod, HyperMax Technologies
A: The sequence can vary somewhat from truck-to-truck and year-to-year. For example; the automatic transmission on a later model Dodge (2003+) or on a Duramax will handle slightly more horsepower and torque than an older Dodge or Ford truck. With 6.0L Power Strokes, ATS utilizes our E-Power tuner along with the transmission upgrades since it also remaps the transmission parameters for improved shifting and pressure control.
Later trucks may need different fuel system modifications versus an earlier model. With earlier 12-Valve Cummins trucks the P7100 pump can be modified to flow large quantities of fuel, whereas the common rail motor will need our Twin CP3 system to match the fuel volume.
With some trucks such as the 6.0L Power Stroke the need to upgrade the turbo can present itself much earlier. Many times the charger update is essential due to failure of the stock variable turbo. - Matt Bozarth, ATS Diese
A: Not really. An engine is an engine-it doesn't care how the fuel is delivered so long as it gets there. However, the method changes. For example, earlier Cummins engines would employ modifications to the injection pump such as our Fuel Stop Plate, (instead of an X-Tuner) as well as 3000-rpm governor spring kits. For some extra performance above the electronic modules, we also offer larger injectors that flow more fuel.
If you have a Dodge-Cummins, we would also recommend our Pulse cast iron exhaust manifold, and if you have a Duramax, we would recommend our Full Bore driver side exhaust manifold that replaces the pinched-down factory unit.-Brain Roth, BD Power.
When in the performance enhancing sequence should one upgrade the turbo?
A: The need for turbocharger upgrades is partially dependent on the age of the vehicle and partially dependent on the needs of the vehicle owner. Older trucks such as early model Dodge Cummins and Ford Power Strokes used non-wastegated turbos that might benefit from a smaller turbine housing and the addition of a wastegate. Later model trucks with variable geometry turbos may not need to be upgraded for most purposes. Hard core racing enthusiasts are often looking toward compound turbo systems to build massive amounts of boost. - Peter Treydte, Gale Banks Engineering
Banks Techni-Cooler intercooler systems are superior to stock. Everything about Techni-Cooler is bigger. It includes large 3.5-inch mandrel-bent, high-flow boost tubes, a wide-open inlet and outlet; a 19 percent thicker core area to produce a 21 percent improvement in volume. The units have big, high-efficiency all-aluminum end tanks instead of the stock plastic ones that can rupture under high-boost conditions for all popular turbo-diesels.
Banks makes a more efficient exhaust manifold for Cummin diesels in Dodge Rams. They also make a much better intake for the awkward intake on these engines.
Banks offers exhaust systems for 6.5-liter and even retro-fit turbo systems for the earlier 6.2-liter engines.
Bully Dog's free flowing exhaust system for most popular makes and model of turbo-diesel applications.
Turbocharged diesel engines move huge volumes of air, so a high-flow exhaust system is critical to ensure maximum power output. BD's X-Hale exhaust systems are made from seamless, 4-inch mandrel-bent stainless steel tubing, and feature a high-flow 6-inch polished 304 stainless steel muffler and polished 304 stainless steel tip. The X-Hale exhaust system results in more power, better sound and quicker turbo response.
SMOKERS Stacks are back asserts MBRP Inc. You see them on trucks front the drag strip to Main Street, these pipes perform with style, awesome sound and incredible power.
The Edge Juice communicates directly with engine's ECM, from which it receives vital engine and fuel system information. This enables the Juice to alter the fuel curve to pump up your power. The Attitude displays all the information a set of gauges would, including rpm, boost, EGT, backdown percentage and more. The Attitude will automatically monitor exhaust gas temperature (EGT) and de-fuel the engine to prevent excessive EGT plus the monitor is capable of flashing warnings at user set levels of EGT and boost.
The Hypertech Power Tuning Module #41042 (for 2003-04) and #41045 (for 2005-06) maximizes the performance of 6.0L Power Stroke diesel engines in Ford trucks and SUVs and delivers powerful, street-legal tuning for towing the maximum loads allowed by vehicle manufacturers.
Bully Dog's Triple Dog Outlook combo allows you to adjust the downloader on the fly inside your cab with their Outlook Monitor. Every program in the downloader is adjustable on the fly, meaning you can adjust horsepower levels while driving using the Outlook Monitor.
The Rapid Power performance module will increase towing performance, drivability and fuel mileage. This module has three horsepower settings of Stock, Towing (40 hp) and Performance (103 hp). This module also includes Tranny Smart software to protect your transmission against unnecessary damage.
BD's X-Tuner simply plugs into the OBD II port underneath the dash, and re-flashes the engine control unit (ECU) with any one of several BD-engineered performance programs. Imagine up to 130 additional horsepower and 250 lb-ft of torque.
BD Power says that torque converters have two stages, a fluid coupling that occurs first when you are starting, accelerating or pulling up a big hill. When you are cruising at a constant speed the lock up portion of the converter is engaged and 100 percent of each rpm is transferred through the converter, just like through a standard clutch. They have redesigned the fluid coupling by reshaping the stator fins to achieve a higher ratio of rpm transfer through the convertor when in a fluid coupling. The lock up clutch material and surface area is enhanced to hold the high engine torque on performance Diesel engines.
