There is a wide array of upgrades available to improve the appearance and performance of your vehicle, be it gas or diesel-powered. Surely, you’ve thought about getting an upgrade or two over a million times since the day you got the keys to your truck.

Despite the strong urge to make some modifications to enhance your truck’s engine or amp up its look, you end up delaying it as much as you can, mostly because you’re intimidated by the immensity of the project.

When it comes to vehicle upgrades and improvements, it’s not unusual to think these would warrant an engineering and mechanical degree or at least a vast amount of knowledge in taking on such technically complex tasks, especially if you’re dealing with a diesel engine. 

It’s time you know that this kind of thinking is hardly true. You just need to have a sound grasp of some important automotive principles, a bit of mechanical know-how, and maybe a lot of patience. 

Aside from major repairs and large-scale upgrades, there are a number of vehicle modifications you can work on to boost your truck’s appearance and engine performance, such as installing a new set of tires, changing your old spark plugs with new and better-performing ones, and setting up a backup camera and reverse sensors.

Diesel Truck Engine Upgrade Guide

Maybe you just got your first-ever diesel-powered truck and want to maximize its potential while getting the most bang for your buck, or perhaps you’ve had it for quite a while now and noticed there is room for some performance improvements and modifications. Regardless of your reasons, surely you’ve thought about upgrading for your vehicle.

Thankfully, there is a myriad of aftermarket products and engine upgrade parts available today, from vehicle performance to engine efficiency. With hundreds of options to explore, it can be overwhelming to decide where to start. We’re here to lay down the facts about the best upgrades to consider for your diesel pickup truck. 

ECM or ECU software/chip upgrades

What it is: The Engine Control Module (ECM) is a small but mighty black box that almost exclusively dictates your truck’s engine performance. Although engineers know how to maximize your diesel engine’s full potential, EMCs’ factory tuning usually remains conservatively calibrated to meet government restrictions, emission standards, and fuel economy requirements. This leaves truck enthusiasts lots of room to improve the settings and allow it to handle more power.
By reprogramming the endless lines of computer code or replacing the ECM entirely, you can customize vital engine parameters according to your preferences. You can dictate your engine’s functions including air-fuel mixture, maximum RPM, torque, horsepower, and fuel efficiency.

Pros: One of the advantages of reprogramming your truck’s EMC is that it is an easy way to boost your engine’s overall performance. EMC upgrades are very versatile, allowing you to alter hundreds of thousands of computer code to direct all the electronic functions to reach your truck’s full potential.

Con: Depending on your tuner, it’s essential to note that by tinkering with the EMC’s settings, you could be running the risk of voiding your truck’s factory warranty. It’s often safer to choose an in-line tuner as it doesn’t change the factory programming. Simply unhooking this type of tuner returns the EMC to its original factory settings. Unlike in-line tuners, an integrated tuner leaves a footprint when reinstalling the factory tuning which could render your engine’s warranty invalid.

Exhaust upgrades

What it is: Exhaust system plays a key role in your vehicle’s performance. Your engine’s exhaust system is engineered to efficiently reduce heat while forcing out post-combustion gasses. Stock mufflers and exhaust are designed to limit noise and emissions by using a small-diameter pipe with some unnecessary bends and pinches that restrict exhaust flow. 

Pros: Unlike stock exhaust systems, aftermarket performance exhaust systems have a wider diameter opening and fewer bends, increasing the exhaust flow and lowering exhaust gas temperature (EGT). In allowing your engine to breathe better, it can produce more power, boosting torque and improving horsepower produced by the engine by roughly 10 – 20 HP. 

Cons: Exhaust systems are expensive. Luckily, most come with easy-to-follow instructions to help you complete the installation by yourself rather than hiring a mechanic, which significantly reduces the total cost. Another drawback is ensuring the quality of aftermarket parts as they are not engineered and created equal. With a wide array of brands and exhaust options, it’s easy to buy a low-quality product by mistake. So before purchasing, make sure to do your research and ask your local auto shop or trusted mechanic for advice.

Turbocharger upgrades

What it is: When it comes to increasing your truck’s horsepower and getting more out of your diesel engine, installing a performance turbocharger is a great investment and one of the best options. The turbo works by forcing higher volumes of air into the engine’s combustion system than with a stock engine, pressurizing the air intake, thus giving it more power.

Pros: A typical stock engine that comes with a turbo is designed to increase airflow three to four times over a non-turbo engine, while an aftermarket performance turbo can boost airflow five to ten times above a non-turbo engine. Upgrading and installing a turbo allows your truck’s diesel engine to generate more power and keep exhaust gas temperatures (EGT) down, resulting in increased efficiency and performance. 

Cons: Proper installation is key in ensuring its effectiveness. Unfortunately, completing the installation of turbochargers is extremely technical and difficult. You may need to hire a trusted mechanic to do the job for you as even minor mistakes can cause major damage within the engine. Also, some turbochargers, especially large turbos, require time to spool up, causing a delay in boosting your engine’s power. Another disadvantage is that turbochargers need additional plumbing and engine oil as it can get dangerously hot. 

Intercooler upgrades

What it is: After upgrading your turbo, you are going to want to upgrade your intercooler. In a turbo diesel engine system, the intercooler is designed to maintain the boost pressure and cool the air from the turbocharger before it reaches the combustion chamber. 

Pros: By cooling the ambient air temperature from the turbo exhaust and making the air much denser, the intercooler boosts your engine’s horsepower during combustion. Cooler and denser air also means lower exhaust gas temperatures (EGT), allowing your engine to perform even better and more efficiently. 

Cons: You must pressurize a larger volume of space, thus requiring more air. This makes the effects of turbo lag more noticeable.

Air intake upgrades

What it is: A new intake system is an inexpensive aftermarket upgrade. If you are looking to further improve the airflow and increase the performance of your engine, a new and upgraded airflow kit will do the trick. Usually, stock intake systems restrict airflow by having a small opening, drawing in less cool air, while a modified intake system sucks in cool air, even from outside the engine housing. By constantly hitting the engine with cold air, it allows more oxygen to burn during compression.

Pros: Because an upgraded intake system allows more air to flow and get to the engine, you’ll experience a significant increase in your engine’s horsepower by up to 20% to 30%. A new intake system also gives you better fuel economy. 

Cons: It increases the risk of hydro-locking. This happens when moisture from the cool air pools together in your engine, which could lead to engine and mechanical failure. An upgraded intake system also causes a considerable increase in your pickup truck’s engine sound.

Transmission upgrades 

What it is: Although it’s technically not an engine modification, transmission upgrades are necessary when bolstering your pickup truck’s engine power to avoid encountering problems like bent forks, broken shafts, and worn-out synchros. Stock transmissions are built to handle the power of the standard factory specifications—they’re not designed to withstand too much power. A high-performance torque converter can help your transmission manage the stress of all your engine modifications and prevent deterioration of the clutch surface and pad surface.

Pros: Transmission upgrades help improve acceleration and increase performance by optimizing its gear ratios. 

Cons: The upfront fees of having your transmission upgraded can be overwhelming, but it is definitely worth every penny. As it takes mechanical understanding and skills to install the upgrades, it could also be challenging to find a local auto shop or mechanic you can rely on. 

Injector upgrades

What it is: Aftermarket injectors complement your ECM and intake upgrades by allowing more fuel to flow freely and reach the engine (compared to stock injectors), giving your engine a higher range of power output

Pros: Aftermarket injectors increase engine performance, horsepower, and fuel efficiency, with some claiming to increase horsepower by 50 to 100 HP.  Several top-notch injectors also work to increase pressure for better fuel atomization. 

Cons: Installing the correct injectors for your engine can be a little bit tricky as there is a chance you could overdo it, allowing too much fuel without proper tuning can create excessive heat and smoke.

Camshaft and valve upgrades

What it is: It is a cast iron or steel shaft that uses lobes or cams that push the valves open and close when it rotates. Upgrading the camshaft allows more air into the inlet valves as it lifts higher on the lobe of the camshaft. This increases the valve’s stroke length, and in turn, boosts the engine’s horsepower. Also, the size, shape, and position of the cams determine the timing of the value and dictate your diesel engine’s performance at different speed ranges.

Pros: Installing a performance camshaft can help boost your engine’s performance. By upgrading it to have a higher lift on the lobe, extended valve stroke, and longer duration of the valves left open, it lets air into the combustion chamber, thereby boosting the engine’s horsepower. 

Con: The biggest drawback of upgrading your camshaft is that it takes an experienced and skilled mechanic to determine suitable specifications and carry out the modifications. 

Performance monitoring

What it is: After your modifications, it is vital to monitor newly installed systems and upgrades and work on fine-tuning your performance engine. With all the new changes in your truck’s engine, it would be quite challenging to keep track of every little thing going on, which is why it’s recommended to also install gauges that can help you keep a close eye on the health of your engine.

Pros: Investing in additional instruments like a pyrometer, boost gauge, and tachometer can help you measure exhaust gas temperatures (EGT), RPMs, and health of the turbocharger, which will aid in making adjustments to extend the life of your engine. 

Con: Regular tune-ups and performance monitoring can be time-consuming, but it’s worth every second as it improves your vehicle’s overall performance and gives you peace of mind knowing that your engine is running smoothly. 

Diesel fuel additives

What it is: Diesel fuel additives are formulations of chemical compounds that are added to diesel fuel to modify its properties and provide an even cleaner combustion. A number of these additives aim to boost performance and improve fuel efficiency. 

Pro: For a good price (most diesel fuel additives are priced at $20-$50), these treatments improve engine performance overall—whether it’s through corrosion inhibitors, deposit modifiers, or cetane improvers. There are several formulas out there, so you’ll be able to find a product that addresses your vehicle’s needs. That said, you have to understand which properties you need to address because although multifunction treatments exist, no one additive can address everything.

Con: More isn’t necessarily better. You may inadvertently cause adverse effects like poor filterability or even blockage if you add more than the prescribed dosage.

What’s Your Next Engine Upgrade?

With a wide array of engine upgrades available in today’s market, it sure is difficult to know where to start. Your decision should not just be about opting for the top-rated pickup truck upgrade, but also consider your budget and your goals—be it speed, acceleration, smoothness, efficiency, or power. This will help you get the most out of your money and ensure that you breathe life into your vehicle. 

Although some of the modifications mentioned in our list can be done by yourself, there are others that require in-depth knowledge and technical know-how to find the right parts and skillfully carry out performance upgrades, specifically for pickup trucks and their respective diesel engines. With help from the experts at Pure Diesel Power, you won’t have to worry about a thing because you’ll know you’re in capable hands.