Ford Power Stroke Project Outcast Part 1 Photo Gallery
Aftermarket Tuning and OE Fuel Pressure Upgrade
Mike McGlothlin –
Aug 1, 2012
Photo 1/9 | project Outcast Part 1 2003 Ford F 250 Next To Chevys And Dodges | Have you ever felt this way with your 6.0L…outnumbered by the competition? Don’t worry, we’ve got your back. The next year of upgrades performed on this 6.0L Power Stroke are intended to help make you more comfortable owning an ’03 to ’07 Super Duty, show you how to make it reliable, and reveal ways to make it more powerful.
Photo 2/9 | project Outcast Part 1 2003 Ford F 250 Next To Chevys And Dodges | Have you ever felt this way with your 6.0L…outnumbered by the competition? Don’t worry, we’ve got your back. The next year of upgrades performed on this 6.0L Power Stroke are intended to help make you more comfortable owning an ’03 to ’07 Super Duty, show you how to make it reliable, and reveal ways to make it more powerful.
Photo 3/9 | project Outcast Part 1 ford 6 0l Power Stroke | Aside from a Brute Force air intake system from AEM and a Silverline 4-inch turbo-back exhaust, no other potential power-adders were on the truck when we got a hold of it.
Photo 4/9 | project Outcast Part 1 2003 Ford F 250 Super Duty Extended Cab | With just 63,000 miles on the clock, we figured this ’03 F-250 would be the perfect candidate for all our testing in the year ahead. And even though the owner has already scrapped the EGR system and added head studs, we’ll still be tackling an EGR delete and a head stud install in the coming months. For those of you without lifts (or who don’t like pulling engines), the head stud install will be performed without pulling the cab, and with the engine still in the truck.
Photo 5/9 | project Outcast Part 1 2003 Ford Super Duty On Dyno | On the Randall’s Performance SuperFlow dyno, the truck distributed just 251 hp and 388 lb-ft to the rear wheels in stock form. Peak horsepower was made at 3,400 rpm, but due to the automatic transmission’s factory kick-down strategy (and inability for a gear to be manually selected), only a 20 percent load could be applied to the truck at lower rpm to keep it from downshifting (hence the low torque number).
Photo 6/9 | project Outcast Part 1 sct Tuner | In order to address the transmission’s downshifting problem, Elite sent us an Insanity dyno tune along with an Insanity street file. Its dyno tune holds the transmission in Fourth gear (and the torque converter locked), which allowed us to make a complete rpm sweep and load the truck harder. Other than that, the Insanity street file is the exact same thing as the dyno tune. The street file pulls extremely hard, and transmission shifts are just how we like them—nice and firm. *Note: All Insanity tunes disable EGR (whether it’s deleted or not), but without head studs, head gasket issues will eventually surface.
Photo 7/9 | project Outcast Part 1 fuel Pressure Regulator Spring Comparison | Notice the difference in length between the blue fuel pressure regulator spring (top) and the stock spring (bottom)? Because the spring sits against a check valve that returns excess fuel to the tank, installing the longer spring causes the valve to open later. This means more pressure is made at the regulator, and in theory, more pressure reaches each injector. Once the blue spring was installed and everything was buttoned back up, we cycled the key a few times to prime the fuel system.
Photo 8/9 | project Outcast Part 1 secondary Fuel Filter Housing And Parts | Here you can see everything that gets removed from the secondary fuel filter housing for the blue fuel pressure regulator spring upgrade. (Note: You don’t have to remove the fuel filter housing assembly to perform the upgrade.) To gain access to the fuel pressure regulator spring, the regulator cap has to be removed. It requires a T27 Torx socket wrench to get the four bolts out of the regulator cap. The blue-spring upgrade (PN 3C3Z-9T517-AG) comes with everything you need, including a new cover and all hardware.
Photo 9/9 | project Outcast Part 1 fuel Pressure Gauge | Ford Power Stroke Project Outcast Part 1