7.3 factory turbo mild performance upgrades

[TheRadBaron]

Hi fellas. This is my first post here. I'm a long time light truck mechanic but I'm new to the Ford/IH IDI (and modifying diesels in general).
I recently picked up a '94 F350 CCLB dually with the factory turbo 7.3. The truck has been in the family for a long time and it's been well maintained and it runs great. It was totally stock when I got it. I've spent the last few months learning about the IDI and I have fresh coolant with SCAs, etc.
I'm doing a VF5 swap and some engine work as well. The truck will mainly be used for towing. I'd like to get a bit more power but most of my emphasis will be on longevity/durability. Here's what I have planned:

-Free flowing intake and intercooler setup from Classic Diesel Designs
-2.75" downpipe from Moose Diesel (cab seam has been clearanced)
-Full 4" exhaust from the downpipe, with straight-through muffler
-Bellowed up pipe and mandrel bent crossover pipe from CDD
-Boost and EGT gauges to monitor things

I've read about adjusting the wastegate for a bit more boost. I've drilled out the punched divots in the factory wastegate linkage so it's adjustable now. I'm thinking that 12psi max will be a good number? From what I've read it sounds like a safe level with factory head bolts. Thoughts? Is that achievable/good idea with the factory turbocharger?
Also turning up the fuel on the IP a bit. Any guidelines on how much to turn it up? IP and injectors are stock.

I have a timing tool for the engine with the piezo sensor that goes around an injector line. Will the addition of more boost and an intercooler, and majorly freer flowing exhaust, have any effect on the timing requirements? What's a good number to shoot for?

Anything else I'm missing or that I should consider?
Thanks.

 

[IDIBRONCO]

I'm thinking that 12psi max will be a good number? From what I've read it sounds like a safe level with factory head bolts. Thoughts? Is that achievable/good idea with the factory turbocharger?

I think that's a good idea. You'll be happy there.

Also turning up the fuel on the IP a bit. Any guidelines on how much to turn it up? IP and injectors are stock.

Personally, I wouldn't go any more than one flat if you're turning up the fuel before installing a pyro. I do tend toward the cautious side on that to be safe. By "stock" I hope that you mean that the pump and injectors have been rebuilt to stock specs. If they are original, you either have a super low miles truck, or they need to be replaced.

Will the addition of more boost and an intercooler, and majorly freer flowing exhaust, have any effect on the timing requirements?

I don't believe so.

What's a good number to shoot for?

This is a sticky one. Every set up likes a little bit different timing setting. All we can give you is guidelines. Since you've done research, you probably know that the rebuilders recommend 8* as a starting point. I've seen quite a few people say that their turboed engines like the timing to be more retarded that 8*. 7* might be ok, but you'll have to experiment until you find a spot where the engine seems to perform the best.
Personally, I'd do all of the add ons before I went too wild with turning up the fuel or boost. Once again, that favors caution.

 

[TheRadBaron]

Thanks for the response. I already have the boost gauge and pyro installed. Both are Auto Meter. I took the truck on an extended full throttle run up to about 80mph and heldn it there for a few miles. EGTs got up to about 1150 toward the end. This seems a little high to me but I’m not sure if this is normal or not. Boost got to about 8psi.
I’m hoping the intercooler will help with this. I’m also not sure where the timing is at right now. I doubt it’s ever been properly set.
The IP has been recently rebuilt by a local shop. I’m not sure about the injectors. I figure it would be a good idea to replace them and I’ll do that soon. I have the R&D fuel return rails coming so I guess now would be a good time.
I agree about not doing any fuel tuning until everything else is installed. I have all of these parts in hand or in the email already so that’s the plan.
As far as injectors go, should I go one step from stock replacements? “Stage 1” so to speak.

 

[IDIBRONCO]

Those EGTs are on the high side. Especially considering that you were empty. Timing could be a factor in that. Since you are aware of this, you wouldn't have to do anything until the injectors come in. You should, at least check the timing after installing them. You'll probably have to adjust it then. Just drive by the pyro. I'm not going to recommend either way on the injectors. Stock injectors will deliver quite a bit of fuel. Stage 1 injectors cost more. On the other hand, I've seen a few people say on here that their engine idled smoother with Stage 1 injectors. Maybe it was a coincidence, maybe it wasn't. I have no idea. Personally, being a tight ***, I wouldn't buy Stage 1 injectors unless I was planning to go with a pump that's at least a 110cc pump. That's just me though. 8PSI of boost sounds like everything's working pretty well for a stock turbo set up. That's about all you'll see out of one. My recommendation is to leave everything how it is right now until you have all of the upgrade parts installed. Just installing the larger down pipe and exhaust might help to lower your EGTs. If you have the money, a freer flowing intake would be a good investment. The stock air box is restrictive. I've seen people mention that their EGTs went down after removing the stock air box. I'll add that I feel like anything that helps the stock set up perform better is worth the money. That would be things like the bigger exhaust, less restrictive intake, and an intercooler. I'd buy those things before I wanted a bigger IP or turbo.

 

[TheRadBaron]

Right on. Your opinion on the mods is about the same as mine. I don’t have any immediate plans for a bigger IP or turbo.
I do have a free flowing intake coming with the CDD intercooler kit.
I’m thinking these mods are going to make for a great running truck without sacrificing any durability or longevity. I was already pretty happy with how it towed even in stock form. But I didn’t have a pyro installed when I was towing with it.
I’ll look into the injectors a little more to decide which way I want to go. The Stage 1s from CDD do sound pretty slick.

 

[DirtyWood]

Where did you install the pyro probe? 1150 is about the safe limit when I'm driving. I think you can push a bit more boost like 10-12psi.

Don't forget about R&D IDI, I just ordered a new IP and some injectors.


Edit: As far as mild upgrades go I recently added a fuel pressure gauge after the fuel filter header and it is very helpful to see how well the system is flowing. I also blocked off the return port on the filter header that connects to the #1 injector and gained about 1psi. The engine seems to run better with fuel pressure 3-5psi.

 

[TheRadBaron]

Probe is installed on the drivers side exhaust manifold, just downstream of the rear cylinder.
Good call on R&D, too. I’ll check out their injector offerings.
I was planning on adding a fuel pressure gauge as well.