2003 Ford F-250: Project Outcast Part 7

More Fuel For The Fire

Mike McGlothlinJul 1, 2013
A host of fuel upgrades made their way onto our 6.0L-powered ’03 F-250 this month, all of which have us knocking on the door of 500 rwhp. We bumped our injector size from Elite Diesel’s 155cc to its 185cc units, installed a regulated return from Strictly Diesel and, knowing that our fuel demand in the future will only be growing, bolted on a FASS system. From there, we re-tuned the PCM, courtesy of Elite Diesel, and returned to the dyno.
Photo 2/14
The combination above coupled with the Garrett PowerMax turbo makes for a snappy, hard-charging truck on the street, and one that could run a mid-13-second quarter-mile at the track. Exhaust gas temperature and smoke are still very manageable as well. However, this will begin to change next time, as we plan to push the off-the-shelf Garrett drop-in to the limit (maybe even over the edge) with an even larger set of injectors. Stay tuned for Part 8.
Photo 3/14   |   At the heart of this month’s horsepower recipe sits a set of Elite Diesel Engineering’s Stage 2 Tow Power injectors. They flow a maximum volume of 185 cc and are fitted with 70-percent-larger-than-stock, extrude-honed, 8-hole nozzles (factory nozzles are 6-hole). While these 185/70 injectors retail for $3,250, Elite also offers a Stage 2 DIY injector kit for budget-minded enthusiasts, which allows you to build your own set for just $950.
Parts List
Part: Vendor: Details: Price:
Injectors Elite Diesel Engineering Stage 2 Tow Power injectors, 185cc, 70-percent nozzles (8-hole) $3,250
Regulated Return Strictly Diesel More efficient fuel flow; fuel flows through heads, eliminating dead-heading in fuel rails $674.95
Fuel Supply System Strictly Diesel FASS Titanium Series 125-gph system (T-F14-125G) $692.55
Regulator Spring Strictly Diesel Custom, 75-psi regulator spring for FASS pump $5.95
LargeMouth Kit CFM Plus Intake elbow with 3½-inch opening, 3½-inch intercooler pipe, hoses, and clamps $439.95
Total Price $5,063.40
*Opting for Elite’s DIY injector kit (mentioned earlier) will save you $2,300.
Dyno Results
At 485 hp and 912 lb-ft, we picked up 32 hp and a whopping 100 lb-ft this month. The additional low-end grunt is available at lower rpm, too, which allows the truck to get up to speed (under normal acceleration) much quicker. The truck is also less prone to downshift when pulling grades in overdrive (no more pesky gear changes and wasted fuel). That is to say, the setup illustrated this month gives the 6.0L Power Stroke the kind of low-end torque many ’03 to ’07 Super Duty owners wish they’d had from the factory. Overall, we’d say the PowerMax turbo is a good match for the 185cc injectors. Ample boost is always on tap, such as 6 to 7 psi at highway cruising speeds, and it lights instantly when we hit the throttle. While cruising at 70 mph, the pyrometer now reads 800 degrees, where it used to say 680—but this could be addressed by tweaking the PCM tuning a bit more to cool things down.
Photo 13/14   |   Back on the dyno (and under load) at Randall’s Performance, we saw 33 psi of boost and EGT peak at 1,500 degrees. For the majority of each dyno run, EGT stayed below 1,350 degrees, so a quick spike to 1,500 didn’t worry us. ICP voltage held strong at 4.7 volts (meaning more than 3,500 psi of injection control pressure), fuel supply pressure never budged off of 65 psi, and an ideal injector pulse width of 2.5 milliseconds was observed.
Photo 14/14
*Dyno pulls were made in Fifth gear (converter locked) *Dyno runs began at 55 mph and ended at 95 mph
*30 percent load applied *DynoJet correction factor
Then and Now
Previous Horsepower: 453 hp at 3,200 rpm
(Elite Diesel Insanity tuning, Stage 1 FICM, 155cc injectors, PowerMax turbo, DieselSite high-pressure oil pump)
Current Horsepower: 485 hp at 3,100 rpm
(Elite Diesel Insanity tuning, Stage 1 FICM, 185cc injectors, PowerMax turbo, DieselSite high-pressure oil pump, FASS fuel system, Strictly Diesel regulated return)
Previous Torque: 812 lb-ft at 2,600 rpm
(Elite Diesel Insanity tuning, Stage 1 FICM, 155cc injectors, PowerMax turbo, DieselSite high-pressure oil pump)
Current Torque: 912 lb-ft at 2,450 rpm
(Elite Diesel Insanity tuning, Stage 1 FICM, 185cc injectors, PowerMax turbo, DieselSite high-pressure oil pump, FASS fuel system, Strictly Diesel regulated return)

Sources

CFM Plus
Vista, CA 92081
760-598-2478
www.cfmplus.com
Elite Diesel Engineering
Pueblo West, CO 81007
866-631-8518
www.elitedieseleng.com
Fass
Spokane, WA 99223
866-379-8685
www.fassride.com
Strictly Diesel
Scottsdale, AZ 85260
480-922-8769
www.strictlydiesel.com
Randall's Performance and Accessory
Gladstone, IL 61437
309-627-2500
http://www.randallsperf.com
Fuelab
Litchfield, IL 62056
1-217-324-3737
www.fuelab.com

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