500 Horsepower
Reaching 500 hp with an engine rated for 235 is a challenge in itself. But thanks to the recent diesel boom which we have all contributed to, it is becoming easier to reach. High-flowing intakes and exhaust systems are necessary and are usually one of the first modifications made by enthusiasts. For 500 hp, a 4-inch exhaust is sufficient and available pretty much anywhere.
To handle the air requirements needed for 500 hp, a 64 mm to 66 mm turbocharger is needed.
Either turbocharger is capable of handling the air, but the 64 mm is better suited for daily driving, while the 66 is better for a weekend warrior and someone with top-end in mind. While changing the turbo, a higher flowing manifold will help reduce backpressure and lower exhaust temperatures.
For the fuel requirements, an aggressive programmer teamed up with a fuel box make a great combination. Together they tell the pump to stay on and pump out lots of fuel and adjust the timing to make big power. To take full advantage, the VP44 pump needs to be reworked to flow more. So, sending it out to someone like PDR, to have them custom build/modify the pump to flow and support the 500 hp is key. In order to keep up with the fuel demand from the modified VP44 pump, an upgraded lift pump is required.
A good lift pump will flow a very high volume but do it at a high pressure. On the other side of the spectrum are the injectors. They flow very little (relatively compared to a fuel pump) at extremely high pressure. So, to flow the amount the VP44 pushes, 150-175 over injectors are needed.
The stock automatic transmission won't handle this type of power very long, if at all. So, a billet input shaft and an upgraded set of clutches will help to hold the power. Depending on the driving habits of the driver, billet intermediate and out put shafts might be a good idea if the driver demands performance at the push of the pedal. A higher stall converter will help spool the 64/66mm turbo easier and make daily use much easier.