Ford 6.0 Turbo Upgrade – Greater Performance for a Great Engine

If you have a vehicle powered by the Ford 6.0 Power Stroke diesel engine, you probably love it because this engine is known to be one of the best diesel engines in America. This engine was introduced in 2003 to replace the giant - the 7.3 Power Stroke. And Ford did everything to make this engine better than its legendary ancestor.

Key features and my opinion about the engine

• Production years:2003-2009
• Average lifespan of 6.0L Power Stroke:320,000-350,000 miles
• Fuel supply type:direct injection
• Power range:325 hp
• Fuel efficiency:bad
• Engine block material:cast-iron
• Engine reliability score:low
• The most common problems:EGR cooler and oil cooler problems, fuel pump issues, head gasket problems, oil pump failing.

Main specs and features of the 6.0 Power Stroke

The engine was introduced almost 20 years ago but it's still one of the best diesel engines in the series. No, it wasn't a problem-free engine, and the next Power Stroke was probably even better. But still, this truck engine was really good compared to those rare diesel engines in America.

We don't want to take a lot of your time telling you about the 6.0 Ford engine specs or making you read those dull tables. We just want to give a quick overview of what you get when you are driving the vehicle equipped with the 6-liter Power Stroke diesel. And here we can tell you a lot of wonderful things.

Here are some of them:

• this engine was meant to power the trucks and vans made by Ford, many heavy-duty and light-duty trucks and also E-Series vans got this engine;
• also, Ford Excursion SUV was powered by this engine but it wasn't the most popular option;
• the relatively simple and inexpensive fuel injection system is an important advantage, it's not the most durable, but it's not hard to repair;
• it's the V8 engine with 4 valves per cylinder, the construction is solid and very simple for maintenance and repair;
• the turbocharger is as simple as a rock, it's a single turbocharger with the so-called variable vane geometry;
• the engine offers 325 horsepower and 570 lb-ft of torque, it's not bad even for heavy-duty trucks;
• the longevity of this engine is wonderful, it can last 250,000 to 300,000 miles with good maintenance.

Among its main problems, we can remember numerous leaks: gaskets, seals, high-pressure oil pump, oil coolers, EGR coolers, and some other parts keep failing. It means you will always see some drops of oil or coolant under your vehicle. But still, these problems are minor and don't affect the longevity of the engine much if not overlooked.

Also, you can think of electrical problems with fuel injectors and some other parts in this engine.

But you can see that mechanically, the engine is great and it won't let you down. It means that you can even try to boost it to get more power, better accelerations, more surprising towing capacity, etc. What about a turbo upgrade? Let's see.

Upgrading the 6.0 Power Stroke turbocharger

As we've already said, the 6.0 Power Stroke diesel engine has a simple single turbocharger which is not very efficient. And yes, you can upgrade it to get at least 50-60 additional horsepower and even some additional torque. Whether you need this or not is a hard question - you have to compare all pros and cons before.

We know two main ways to deal with the turbocharger in your 6.0 Power Stroke:

1) Upgrading the stock turbocharger

We don't recommend this option because it will take you weeks to find appropriate parts. So, in the end, you will basically try to insert a new turbocharger into the old body and this will not be as easy to do as you may wish.

Still, you will get a single turbocharger that will only be a little more efficient than the old one. If you are a highly experienced car mechanic and you will do all the job by yourself, then it may be worth the money you'll invest in it. But if you can't do everything by yourself, you will overpay for labor, eventually, and it won't be very wise.

The only important advantage is that you don't need to rearrange oiling and air intake. Everything looks like an OEM turbo but works a little better. Though, the power gain will not be significant.

2) Bolt-on kits to install in your 6.0 Power Stroke

You may choose another option and go for a special kit. We know at least three manufacturers offering these kits. All you need to do after you buy such a kit is to take off the old turbocharger, bolt on the new one, ensure all connections are placed where they need to be, and start the engine.

Well, you may also need to work with the ECU to ensure it allows higher power. Also, you will need to make sure that the oiling and air intake work properly and don't create problems for your turbocharger.

We see one major disadvantage - the price. A solid kit will cost you about $3,500 or even more expensive. Another $1,000 may be spent on labor because it's not the conventional work.

Also, you will need some ECU tuning and other changes to your car in order to feel the real difference from what you had before.

What else will you need to change?

Unfortunately, just by installing a new turbocharger, you will not make your truck or van fly over the roads because of excessive power. You will need to go a long way to get the results you may feel when driving your vehicle.

Here are some of the main ideas you will need to remember:

1. ECU. Without proper settings of your ECU, you will not feel the extensive power of your vehicle. This means you will need to go to some guys who can tune your ECU in accordance with the new equipment.
2. Air intake. Sometimes, new big turbochargers need more air to work properly. For this, you may need a new filtration system in the air intake and also new air pipes.
3. Fuel supply. Also, for being more powerful, your vehicle will need a better fuel supply. Just because of this, you may need to work with the injectors and with the fuel pump to ensure better pressure. Well, the OEM parts are OK, they just need to get proper settings.
4. Exhaust. You cannot make the engine much more powerful without touching its exhaust system. More gasses will not be able to leave the engine and this will cause worse power in the end.
5. Oiling. The problem with HPOP will be even more dangerous. The new turbocharger will need proper oiling, but once the pump fails, the engine may just kill itself. So, you will need to make sure that everything works properly.

You now see that a lot of steps separate you from having your Power Stroke 6.0 engine that will deliver much more power than now. OEM-built engines are not very efficient. Especially if compared with the fresh diesel engines.

What are the dangerous moments for the Ford 6.0 upgrades?

Is there any danger in upgrading the turbocharger and other parts of your 6.9 Power Stroke engine? Yes, you will get some problems. First of all, you should understand that the longevity of the engine will be worse. It will not be able to go 300,000 miles with no breakdowns and problems.

Also, you should bear in mind that the engine will need better maintenance which means you will need to spend more money on it. If the turbo needs repair, you will have to buy the original parts from the manufacturer of your turbocharger.

One more thing - the fuel consumption will be unpredictable. One turbo kit will allow you to enjoy the same fuel mileage as before while some others will need more diesel fuel to let you feel the power boost. And this also is an important factor to consider. Especially, if you drive a lot.

Final words

We aren't sure you will want to invest in a new turbocharger for your Ford 6.0 engine without changing the intake system, injection, exhaust, and also some other parts. It's important to make sure that you will get the maximum from your investment. So, if you just have a couple of dollars, you may just go to the guys who can tune the ECU and provide you with some extra power.

But if you want a project car, the 6.0 Power Stroke is not a bad option. If you do everything right, the vehicle will be just a diesel beast with moderate losses in durability.