How much horsepower will my truck handle? What turbocharger should I use? What is a safe horsepower level for my diesel engine?
We get asked these questions all the time, so we thought we’d put together some info on what each engine commonly found in diesel powered trucks can handle, how to make more power, and the roadblocks you might face when adding power. The list could go on and on, so for this list we’ll limit it to 600hp max which is a great power level for reliability and overall drivability. All these engines are very much capable of much more, with extensive modifications.
7.3L Powerstroke
Some data, and issues to be aware of, with the OEM Engine:
Forged rods can handle around 700hp. Many have done much more than this, however 700hp is a safe number.
Powdered Metal Rods consistently fail at anything north of 400hp
Stock Injectors only flow enough fuel for 300hp in Super Duty trucks. OBS is less.
The heads have valve issues. We use upgraded valves to remedy this.
Power Packages
Parts listed are the bare minimum needed to achieve the mentioned rear wheel horsepower goal
425hp –
Forged rods are required. Head studs highly recommended.
Regulated Return Fuel System – Removes restrictions in the factory fuel system
Upgraded lift pump
205CC Injectors
23 degree HPOP or DieselSite Adrenaline Upgraded HPOP
KC Turbos Stage 2 Turbo or Garrett 38R equivalent
Custom Tuning
500hp
Forged rods are required. Head studs highly recommended.
Regulated Return Fuel System – Removes restrictions in the factory fuel system
Upgraded lift pump
238 to 250CC Injectors
23 degree HPOP or DieselSite Adrenaline Upgraded HPOP
KC Turbos Stage 2 Turbo or Garrett 38R equivalent
Custom Tuning
600hp
Forged rods and head studs are required.
Regulated Return Fuel System – Removes restrictions in the factory fuel system
Upgraded lift pump
275 to 300CC Injectors
Thumper 2 HPOP or equivalent
KC Turbos Stage 2 Turbo or Garrett 38R equivalent
Custom Tuning
Girdle recommended to stop main flex.
6.0L Powerstroke
Some data, and issues to be aware of, with the OEM Engine:
Head studs are required at any power level to fix this engine’s lack of head clamping power.
Head cracks are common. Make sure you have good heads.
EGR Coolers and Oil Coolers fail. We recommend replacing the oil cooler when coolent and oil temperatures differ by more than 30 degrees consistently. We recommend the use of a quality upgraded oil cooler such as those made by Bulletproof Diesel
6.0L Rods are fairly stout being able to handle upwards of 800hp with good tuning.
Power Packages
Parts listed are the bare minimum needed to achieve the mentioned rear wheel horsepower goal
400hp
Custom Tuning
500hp
175cc Injectors
Upgraded turbo – KC Turbos Jetfire Stage 1 or equivalent
Regulated return fuel system with upgraded 125gph lift pump
Custom Tuning
600hp
Custom Tuning
Regulated Return fuel system with 220gph lift pump
DieselSite Adrenaline HPOP or better
190cc injectors
6.4L Powerstroke
Some data, and issues to be aware of, with the OEM Engine:
Pistons are a weak link at any power level. Good tuning will help stock pistons live. We use the pistons used in the industrial application for this engine which are much more robust.
Rods are very robust being able to handle up to 900hp with the right tuning
The fuel system was very overbuilt for this engine. Fuel mods aren’t necessary until several hundred hp is added.
Fuel lines are a one time use product. They can leak fuel into your oil causing bearing failure. Replace your lines.
500hp is possible with only a tune
Power Packages
Parts listed are the bare minimum needed to achieve the mentioned rear wheel horsepower goal
500hp
Custom tuning
600hp
Custom Tuning
Upgraded Compound Turbos from BD Diesel or KC Turbos
100gph Lift Pump
6.7L Powerstroke
Some data, and issues to be aware of, with the OEM Engine:
The high pressure fuel pump is a common fail point. We recommend either a disaster prevention kit or DCR replacement pump from S&S
The stock CP4 struggles to produce enough fuel for more than 550hp
The factory intercooler fails commonly. Highly recommended when increasing power at all
Exhaust Manifolds crack – Recommend replacing them when replacing the turbo, or if they’re already cracked
Model years prior to 2015 have a failure prone turbo. We recommend using KC Turbos Warlock kit
Power Packages
Parts listed are the bare minimum needed to achieve the mentioned rear wheel horsepower goal
500hp
Custom Tuning
600hp
DCR High Pressure Fuel Pump conversion kit
Fass pump 140gph
KC Turbos Stage 2 Turbo
Custom Tuning
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