If you have the stock intercooler with the plastic end caps, you'd better start looking for a new intercooler! Those things pop EASY! Keep an eye out for a stock metal end cap intercooler or go aftermarket if you can get a good deal on one. Much more than stock boost on the plastic one is asking for trouble!

Jared

 

i'm surprised i haven't blown mine yet (although i think i almost did once). i'm running an mp8 and when it is turned up in 5th and 6th gear i'll roll right about 42#s of boost w/ the stock hair dryer. i'll be upgrading my charger once i get the money but i need to get rid of that crappy intercooler first.

 

thats right i forgot about the plastic intercooler ends

 

Depends on the build date whether you have a plastic tank CAC. The early 05's before 01-05 were the problem ones. Build date at or after that were metal.

 

Pre turbo, keep your egt's below 1200/1250... MAX, Stock head gasket will hold.

 

A stock truck will go to 1400 EGT's no problem if it is an 04.5 or up. I wouldn't go over 1350 on a long grade. What gets the stock headgasket is drive pressure, too much timing, cylinder pressure. Get to far from 1:1 ratio for drive pressure and you can roach it easy unless you have put ARP head studs in it. 50 psi is about max for boost pressure. Some have gone higher and some have toasted the HG at a lower boost psi. All has to do with above statement. It's a balancing act, get it out of whack and kiss the headgasket goodbye.