Photo 2/25 | 002 Aeromotive Psp Diesel Lift Pump Powerstroke Turbo Upgrade | The 6.0L Power Stroke engine in Richard Alvarado’s ’06 Ford F-250 has seen many different parts combinations in its day, with a recent upgrade from a BorgWarner S367 turbo and 250/100 injectors to the current SX-E 369 ’charger and 330/150 injectors. Although horsepower increased from 715 to 736 with these upgrades, Richard feels more oomph is available through a fuel pump swap.
Photo 3/25 | 003 Aeromotive Psp Diesel Lift Pump Powerstroke Pressure Regulator | In an effort to control pressure spikes, the engine is already fitted with an Aeromotive bypass pressure regulator. Since the new pump features an integrated regulator, Richard removes this old unit and reroutes the lines accordingly.
Photo 4/25 | 004 Aeromotive Psp Diesel Lift Pump Powerstroke 11808 | Aeromotive’s lift pump (PN 11808) for ’03-to-’07 6.0L Power Stroke diesels moves 130 gph of fuel at 10 psi. Assuming a conservative .500 brake-specific fuel consumption (BSFC), the pump will easily support 1,400 flywheel horsepower. This figure does not take into account the additional fuel flow provided by the stock pump. The complete lift pump kit retails for a little less than $2,000. GM Duramax (PN 11801) and ’08-to-’10 Power Stroke kits (PN 11807) are available as well.
Photo 5/25 | 005 Aeromotive Psp Diesel Lift Pump Powerstroke Integrated Pressure Regulator | The integrated pressure regulator allows excess fuel to bypass directly through the pump body and back into the tank. Richard sets the pressure at 63 psi. Aeromotive prides itself on designing regulators around the needs of each of its fuel pumps. Although the company won’t reveal its trade secrets, tailoring regulator design to a specific fuel pump model helps maintain steady pressure even as an engine’s fuel consumption increases.
Photo 6/25 | 006 Aeromotive Psp Diesel Lift Pump Powerstroke Cat Filter | The 2-micron Caterpillar 1R-0750 filter can remove the tiniest of contaminants, and the pump’s standard 1x14 thread makes it compatible with various brands of filters as well. The pump’s body features an AN -12 inlet port, and AN -10 outlet and return ports.
Photo 7/25 | 007 Aeromotive Psp Diesel Lift Pump Powerstroke Baffle Sponge Assembly | Most baffle assemblies are designed to keep the pump’s pickup submerged when fuel sloshes around the tank at low fuel levels. Aeromotive goes one step further by adding a foam core that filters out air bubbles to reduce cavitation.
Photo 8/25 | 008 Aeromotive Psp Diesel Lift Pump Powerstroke In Tank Filter | In addition to the pump filter, the system includes a 100-micron in-tank filter to capture larger contaminants. The replaceable filter element is attached to a slick billet-aluminum housing that clamps onto the pickup tube.
Photo 9/25 | 009 Aeromotive Psp Diesel Lift Pump Powerstroke Pickup Tube | Although there is no practical way to avoid a 90-degree turn in the fuel pickup, the tube is mandrel bent to significantly reduce pressure drop and cavitation. An adjustable collar makes changing tubing height easy.
Photo 10/25 | 010 Aeromotive Psp Diesel Lift Pump Powerstroke Fuel Hose Quick Connect | All necessary feed, return, and suction hoses are included. The lines come pre-crimped with J2044 quick-connect fittings to make installation and servicing extremely easy.
Photo 11/25 | 011 Aeromotive Psp Diesel Lift Pump Powerstroke Fuel Tank Removal | When servicing the fuel system, it’s always a good idea to disconnect the battery and to relieve pressure from the lines by removing the tank’s cap. Dropping the tank is a straightforward affair that’s much easier with an extra set of hands. After disconnecting the stock fuel lines, wiring harness, and tank straps, the entire assembly drops right out. Centering a jack beneath the tank helps stabilize it during descent.
Photo 12/25 | 012 Aeromotive Psp Diesel Lift Pump Powerstroke Sending Unit Removal | After unscrewing a plastic retaining collar, the stock sending unit pulls straight out the top. Accidentally bending the float arm is a common mistake, so exercise caution.
Photo 13/25 | 013 Aeromotive Psp Diesel Lift Pump Powerstroke Sending Unit Removal | A 1-inch hole for the new pickup tube should be drilled far enough away from the stock sending unit so the baffle does not contact the float arm. The ¾-inch hole for the return tube must be drilled 2.5 to 3 inches away from the pickup tube. Measuring tank depth is necessary in order to trim the pickup tube to the correct height.
Photo 14/25 | 014 Aeromotive Psp Diesel Lift Pump Powerstroke Cut Pickup Tube | Adding an inch to the tank depth height (13.5 inches total) establishes the correct height of the pickup tube. If it’s still too tall, it can be further trimmed. A tubing cutter makes quick work of the cutting process.
Photo 15/25 | 015 Aeromotive Psp Diesel Lift Pump Powerstroke Return Tube Bulkhead | The baffle assembly must be centered directly beneath the pickup tube. The return tube is designed to sit between the foam and black rubber basket. As such, it needs to be trimmed so the end of the tube rests halfway between the top and bottom of the basket. The J2044 bulkhead connector for the return tube attaches to the underside of the tank with a PTFE washer and lock nut.
Photo 16/25 | 016 Aeromotive Psp Diesel Lift Pump Powerstroke Pickup Tube Installation | With the pickup inserted into the tank, the filter is clamped down onto the tubing. Similar to the return tube, the pickup attaches to the underside of the tank with a PTFE washer and a lock nut.
Photo 17/25 | 017 Aeromotive Psp Diesel Lift Pump Powerstroke Sending Unit Reassembled | Before reinstalling the stock sending unit, ensure the float arm swings freely. Otherwise, the fuel-level gauge will not work properly. A locking collar prevents the top of the pickup from swiveling around. With the tank buttoned back up, the size difference between the stock and Aeromotive pickup tubes is dramatic.
Photo 18/25 | 018 Aeromotive Psp Diesel Lift Pump Powerstroke Fuel Feed Return Lines | Routing the new feed and return lines inboard along the driver-side framerail provides a direct path to the new lift pump. Securing the hoses to the frame with zip ties keeps them out of harm’s way.
Photo 19/25 | 019 Aeromotive Psp Diesel Lift Pump Powerstroke Mounting Bracket | Richard mounts the new lift pump on the driver-side framerail, right behind the transfer case. Thanks to the supplied sandwich brackets, drilling into the frame is not necessary.
Photo 20/25 | 020 Aeromotive Psp Diesel Lift Pump Powerstroke Fuel Hose Routing | After mounting the new pump, connecting the feed, return, and suction lines is a simple push-in affair. The suction and return lines (red) are located on the left side of the pump. On the opposite side, one line connects the stock pump—mounted beneath the driver-side floorboard—to the Aeromotive pump. The port on the regulator outlet (right) attaches to the engine-feed line.
Photo 21/25 | 021 Aeromotive Psp Diesel Lift Pump Powerstroke Wiring Harness | Wiring the Aeromotive pump is as idiot-proof as it gets. The supplied harness simply plugs into the fuel pump on one end and the battery on the other end. The harness includes a relay, as well as a mini-fuse tap that plugs into a switched ignition slot in the fuse box.
Photo 22/25 | 022 Aeromotive Psp Diesel Lift Pump Powerstroke Leak Check Dyno | Before making hits on the dyno, the final step of the installation process involves checking for leaks. Since the Aeromotive pump is a self-priming unit, there’s no need to perform a formal priming procedure. With the leak check complete, it’s finally time to make some power!
Photo 23/25 | 023 Aeromotive Psp Diesel Lift Pump Powerstroke Dyno Graph | The dyno graph speaks for itself. The Aeromotive lift pump was good for an increase of 49 hp and 189 lb-ft of torque at the rear wheels.
Photo 24/25 | 024 Aeromotive Psp Diesel Lift Pump Powerstroke Results Hand Shake | Editor K.J. Jones congratulates Richard Alvarado on a job well done. The PSP boys do some top-notch diesel work, so we plan on joining forces with them again in the future.
Photo 25/25 | 025 Aeromotive Psp Diesel Lift Pump Powerstroke Results F250 Burnout | Billowing white tire smoke sure is beautiful, isn’t it? Despite fueling 785 hp and 1,282 lb-ft, the Aeromotive lift pump still has plenty of flow left in reserve.