Since you already have the gauges, I'd say go to a BHAF or Afe filter to let a lot of good clean air in. get rid of the muffler leave the resonator.
Get the box of your choice and watch the EGT's. You will most likely be ok. Max sustained temp should not go over 1300. Short bursts to 1600 or max gauge of 20 seconds won't hurt it. Assuming your gauge is accurate.
As far as injectors, for best mileage 275's or DD1, some have good luck with DD2's as far as mileage goes.
I'm using DD2's and a comp box, can get in the low 20's.
Each step up in injector will add temp maybe 150-200 degrees as max.
If you go to the 4" exhaust use a muffler or the drone will get you.
It certainly won't hurt to go with the exhaust but some say it isn't needed till 350 hp at the wheels. Some say they loose low end power with a big exhaust.
My guess is that a stock exhaust could have stayed on my truck if I had changed the turbo early. The real restriction top flow/heat issue, is the exhaust housing. With the hy35 there are no options but to change the turbo out.
I just reread you first post and see you have an aftermarket muffler. Is the resonator still on it?
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