Diesel Turbo Upgrades and Options

A popular way to pick up performance is a turbo upgrade. Which diesel turbo options should you consider? How do they affect drivability? We have talked with some of the biggest names in the turbo world and they have given us tips to pick the right option from the start. Whether you have a Cummins, Duramax or Powerstroke you will find three options – drop-in, single and compound turbo kits. In this post, we will go over what experts have told us and how it can help you pick the right turbo setup.

Drop-in turbos combine ease and lower cost, but may not support higher power goals. A drop-in diesel turbo uses the factory turbo with upgraded compressor and turbine wheels, as well as upgraded housings for a remove and replace option. All factory electronics, mounting and piping match up perfectly to make install a breeze. In general, drop-in turbos are built to offer quick spooling off the line but increased air flow to lower EGT’s and support fueling over stock power. This option is best combined with tuning and mild fuel system upgrades where the goal is daily driving, towing and street use. Drop-in turbos typically have a core charge since certain factory components are re-used. If you are looking for the quickest install and demand quick response, a drop-in turbo will be your best choice.

Single turbo upgrades bridge the gap between factory drop-in and compound turbo kits. An aftermarket single turbo upgrade can be overwhelming because of all the choices. Aftermarket companies will offer options ranging from a quick spooling diesel turbo to support 450hp to massive singles designed for 1000HP or more. This is where things get tricky. Each engine will have different rpm ranges where it shines for airflow and response. For example, a 12V Cummins may not spool a 68mm single turbo like a 6.6L Duramax will. Or what’s considered a large single on a 5.9L may be small for a 6.7L Cummins. What is crucial when picking a single turbo is contacting companies who design and manufacture them. You’ll want to contact them and explain your build, supporting mods, future goals and ask them which size turbo will meet your goals. This will ensure what you get meets your expectations and the kit comes complete with what you need to do the swap.

Compound turbo kits offer the best of the both worlds, but come with more cost. Instead of making a compromise on low end response versus top end power on a diesel turbo setup, compounds marry the two. Kits are designed for each engine and model year and use a smaller turbo to feed a larger one. This gives low-end response, mid-rpm efficiency and massive top-end airflow. If you need the maximum EGT control for towing or airflow for cleaning up bigger injectors, this is the option you want. Some companies will offer add-a-turbo kits that keep your stock turbo and combine it with a 72-80mm (or larger) big turbo. Others will replace both turbos for a fresh start and optimum pairing of both turbos. The kits will include all the necessary piping, oil feed line and drain tubes, clamps, downpipe and any electronics the truck will need. Install time is a bit more than the drop-in and single turbo choices, and the cost is higher. But, if your truck demands the most in performance, usable power across the RPM range and maximum cooling for towing heavy loads, this is your best option.

Regardless of the option you pick for a diesel turbo upgrade, it is crucial to choose a kit from a reputable company. Warranty, kits with all the hardware you need and customer support are where reputable kits vary from piecing a setup together. Sure, you may be able to save some money buying all the parts individually, but if something goes wrong, the cost (and potential damage from a turbo failure) falls on the truck owner. Because each truck and the owner’s goals can be different, it also helps to reach out to the manufacturer and ask them questions about the drivability. Companies want a happy customer and the last thing they want to see is someone disappointed because they bought the wrong turbo for their truck.

This post encompasses what we’ve learned about diesel turbo upgrades over the years and we hope it helps you in choosing the right setup for your truck.