Making 500 Horsepower
As with most of the engines out there, this is a pretty reachable mark for most. Intake air filters and exhaust modifications are usually the first parts to be changed, but on the 6.0 Powerstrokes, not all intake filters are created equal.
"The factory Powerstroke filter flows a significant amount and many aftermarket filters don't have the same range"_ says Andy Bennett from Trusted Performance. "Talking to people and asking for before and after dyno numbers on real world trucks is really the only advice I can give you,"_ he continues.
The next step most take is adding a programmer or power module. The SCT programmer has the flexibility for tuners to custom tune the programming for each truck. This helps out greatly when people start changing injectors and adding turbochargers. As more and more power is demanded out of the factory fuel injectors, Tadd Layton from Elite Diesel says, "I highly recommend people adding a regulated fuel return system about the same time they add a programmer. This not only helps keep the fuel injectors fueled, but it also extends the life of the injectors because the piston doesn't score the inside of the cylinder walls due to the factory system not feeding it enough."_
After changing the intake, exhaust and adding a programmer, the truck should be anywhere between 400 and 450 horsepower, depending on the programming. From there, there are two schools of thought. Nitrous can add enough air and cool the charge temperature down enough to get the truck close to 500 horsepower. Or if you want the power on tap at all times, upgrading injectors from the factory 135 cc to 155 or 165 cc injectors will help immensely. The factory turbo can support 500 horsepower with these injectors but the exhaust temperatures will be high. "We recommend people upgrading turbochargers anytime they start upgrading injectors. We try to match injectors and turbochargers as closely as possible to keep exhaust temperatures and smoke down as much as possible,"_ says Bennett.
The factory transmission can survive with a custom transmission tune but upgrading transmission is recommended at this stage as well. In addition to building the transmission, an EGR block-off or delete kit and head studs are, also, recommended.