Worthwhile upgrades during engine replacement?

I’m having a remanufactured 3.5L installed in my truck, and my mechanic offered to install upgrades for free while the engine is out. The turbos are in good shape, so I’m thinking about adding a new intercooler (CAC) and blow-off valves (BOVs). Are these upgrades worth it, or should I focus on something else? Looking for suggestions—thanks!

Here’s a great blow-off valve option: Party horn - Wikipedia

Payton said:
Here’s a great blow-off valve option: Party horn - Wikipedia

Wait, that’s a blow-off valve? I had one installed on the tailpipe! Should’ve asked here first.

@Quinlan
You’ve got it backwards—the duck call goes on the tailpipe!

It really depends on what you’re looking for. If it’s longevity, I’d recommend upgraded exhaust manifolds and coolant lines. Full Race makes excellent parts, though their exhaust manifolds are a bit pricey. The thicker casting helps prevent cracking.

For ease of maintenance, their coolant line upgrades are great when it’s time to replace turbos—stock fittings are a pain.

If you’re looking for more power, you could go with bigger turbos, turbo-to-downpipe adapters, and an upgraded high-pressure fuel pump and injectors.

Other upgrades worth considering:

  • New CAC (intercooler)—you can install this yourself later if needed.
  • Colder thermostat, bigger radiator, and external oil cooler if you plan to tow.

Here are a few links:

@Laurel
Also, if your truck has a lot of miles, it’s a good time to change the transmission fluid and filter. Check for any updates from Ford as well.

I’d definitely recommend the updated Ford exhaust manifolds—they’ve solved the warping issues with the newer design.

A new CAC would be a nice addition too, but personally, I’m not a fan of the noise from VTA (vent-to-atmosphere) setups on these trucks.

If you’re looking for big performance gains, go for:

  • High-pressure fuel pump
  • Lift pump
  • Bigger turbos

With these, you can run E30+ tunes and hit around 500hp. Just keep in mind, stock fuel systems will limit you. I hit 400hp at the wheels with stock turbos, manifolds, intercooler, exhaust, and intake, but fuel pressure became the bottleneck for further tuning.

Get the updated Ford exhaust manifolds installed—they’re a must.

Rey said:
Get the updated Ford exhaust manifolds installed—they’re a must.

Do you know what year Ford started using the updated manifolds? I’ve got a 2019 3.5L.

Kai said:

Rey said:
Get the updated Ford exhaust manifolds installed—they’re a must.

Do you know what year Ford started using the updated manifolds? I’ve got a 2019 3.5L.

I believe they started about two years ago, but don’t quote me on that. When I ordered mine, the supplier sent me one old and one updated manifold. It was a nightmare to sort out (avoid Tasca parts if possible).

Make sure the updated cam phasers are installed. It’s a known issue with these engines.