My E-Fuel Conversion and other things - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 41 (permalink) Old 09-01-2013, 03:41 AM Thread Starter
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My E-Fuel Conversion and other things

The plan.......
Day 1 - Under truck work: mount filters
Day 2 - Top of engine: remove and plumb new system

I bought the kit from No Limit Tuning & Design. Kit came pretty much complete. NLTD uses a Walbro pump and black nylon racing hose in their kit.

Well, I can't leave anything alone and started modifying it. I decided to install a SD Pump and throw the Walbro pump in the spare parts bin. The SD pump came with the pigtail. I wanted to set up the pump for easy removal if it malfuntioned while on the road. The connector for the pump was sourced from a Crown Vic front corner light. I unpinned the CV connector and installed heavier gauge wire.

Mounting the filters was pretty much straight forward.



The filters are Wix 533912 (pre-30 micron) and Wix 533911 (post - 5 micron). The filter heads are Stanadyne FM100 Fuel Manager.

The blue fitting on the pump is Russell 640860 (5/16 Push on EFI fitting). There isn't enough room on the inlet side for the fitting to properly lock. For the inlet side, I clamped the racing hose. Should be alright because it's suction.

I installed a ball valve before the pre-filter. This way if I have to change filters with full tanks, they won't gravity drain.
The rumor is that the front tank doesn't gravity feed--->is totally BS.



The feed line to motor is the bottom line (3/8 tubing) going to the top inner port (closest to frame) of the selector valve. I removed the factory rubber hose and triple clamped the racing hose (-6AN). I decided to use the existing 3/8 feed tubing. The return line was not touched on the frame. I cut back the factory rubber feed hose and attached to the valve. Prior to the valve is a 45* 1/4NPT x 3/8 barb fitting. Yea, I know the brake line needs some attention.

Prior going topside, I started the truck and the mechanical pump was able to prime the filters.

The plan was to re-feed the factory banjo. I bought the adapters so I have mininum work.....or atleast thought so.

The driver side head fitting was leaking. You guys think that leaking fitting caused any performance issues? I wonder why???





So off with the turbo. When I removed the turbo, the collector was all loose and soot was the back side. Yea, I had Bean's brass donuts. I guess they didn't work as they were suppose too. I thought to myself, ahh screw the uppipes, so what if they leak alittle. Remember my original plan, just do the fuel system. The next project was to install 3" plenums, billet wheel and if I felt like it, one piece up-pipe.

So I proceed to cut out the dopey fuel fitting on the driver side head. Cut it out no problem and came right out.

I cut the fuel feed (3/8) and return (5/16) lines in the valley. I used steel compression fittings adapted to -6AN (3/8 tube compression x 3/8 MNPT & 3/8 FNPT x -6AN/JIC) and -4AN (5/16 tube compression x 1/4 MNPT & 1/4 FNPT x -4 AN/JIC). I reused and attached the factory return lines to the regulator. You can see fittings in the lower right hand corner of the engine pic below, I will post close ups of the compression fittings at a later time.

The more I'm touching the turbo collector, the more I'm thinking....fix right right or I'll be removing the turbo again. So out with the up-pipes......Yep, wasted my time cutting the fuel fitting. With the up-pipes out, the fitting would have came right out. This was the leak on the collector.



Now I can use normal fittings to feed the heads. Instead of using nylon hose topside, I went with stainless braided racing hose, figure it's more heat resistant that the nylon stuff. So I made up the passenger side. I had some heat sleeving left over from my race car. I heat sleeve the hose because it's close to the exhaust/DP. That went smoothly. Next I go make up the driver side, I'm short one hose end because I didn't plan on making hoses to feed the heads.

So right now, this how topside looks:



Since everything is apart, I ordered:
- one piece up-pipes
- 3" billet intakes
- billet wheel for the D66 (38R wheel)
- hose reducers for the spyder
- various fittings to finish the fuel lines

Hopefully the parts will be here by Friday (lost a day due to Labor Day). I'm hoping air flow/spool up will be much better due to the exhaust.

Will update this thread with pics of topside.

Billy T.
gnxtc2@aol.com

'97 Black F250HD SC 3.55s, Punisher trans, PI Converter, Dana 60 RSK w/ V & C SD springs,
PIS 175/80s, HB Jr, Comp910s, Smith Bros PRs, ARPs, Fluidampr, IC, E-Fuel, CJC Traction blocks, HFHV IDM, T4/BASB, 262K

Other vehicles
-1987 Buick Grand National (Staged)
-2004 Mercury Marauder
-1993 Geo Prizm (beater)
-2016 F350 DRW Utlimate
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post #2 of 41 (permalink) Old 09-01-2013, 04:02 AM
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Re: My E-Fuel Conversion and other things

Looks good so far. It sucks when one project leads into another.

1997Single Cab Dually
S366 w/Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s,
Corbeau seats w 08 console, 19.5s, Black Interior with swede headliner and visors,
Custom badges, Flight Fab/DIY traction bars.

2012 CCSB F250 Ultimate Lariat.
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post #3 of 41 (permalink) Old 09-01-2013, 04:38 AM
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Re: My E-Fuel Conversion and other things

I'll be starting all this is 2 days.. Good luck looks good

1997 F-250, D60, 8in lift/38s, OUO ladder bars, BTS, Spearco 6.0 IC, SRP 1.1, Irate 468 turbo, Dyno proven tunes, P.I.S 300/200s, ARPs/910s/Smith bros push rods, A1000/sump.

13.043@102.59 on 38s
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post #4 of 41 (permalink) Old 09-01-2013, 04:48 AM
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Re: My E-Fuel Conversion and other things

Good thread Billy. On the pump inlet I made a hose barb by clamping a compression fitting down on it and then cutting off the compression nut. I like that adapter you have on the outlet side.

1996 F250 Powerstroke 4X4 AUTO
DP-Tuner F-6 chip live tuned, BTS Transmission, Garrett 38R Turbo, Swamps Injectors 150cc, electric fuel,
Banks Intercooler, Reflexxions Cowl Hood, 17 degree HPOP, 4" Stainless Magnaflow &
Aeroturbine exhaust, Aeroforce OBD Scan Gauge, Truxedo tonneau cover
Dana 60 Precision Metal Fab RSK and SD Springs
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post #5 of 41 (permalink) Old 09-01-2013, 04:57 AM Thread Starter
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Re: My E-Fuel Conversion and other things

The inlet already has "barb". I slid the hose over the barb and clamped it before and aft of it. The other day I found a replace Doorman fitting for the inlet side.

The Doorman fitting is shorter than the Russell fitting and has that plastic hose shrunk over the barb. I have to cut the plastic hose. The Doorman fitting is plastic. I might install the Doorman fitting. I don't have the part number with me now, it's at my shop.

Billy T.
gnxtc2@aol.com

'97 Black F250HD SC 3.55s, Punisher trans, PI Converter, Dana 60 RSK w/ V & C SD springs,
PIS 175/80s, HB Jr, Comp910s, Smith Bros PRs, ARPs, Fluidampr, IC, E-Fuel, CJC Traction blocks, HFHV IDM, T4/BASB, 262K

Other vehicles
-1987 Buick Grand National (Staged)
-2004 Mercury Marauder
-1993 Geo Prizm (beater)
-2016 F350 DRW Utlimate
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post #6 of 41 (permalink) Old 09-01-2013, 05:24 AM
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Re: My E-Fuel Conversion and other things

I can appreciate you're post. I just did pretty much everything you're doing and then some. A lot of work. You'll be happy in the end you did it yourself, your way and I'm sure you'll be happy with the results.
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post #7 of 41 (permalink) Old 09-01-2013, 02:41 PM
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Re: My E-Fuel Conversion and other things

Diesel site has a new Billet Wicked Wheel SPECIFICALLY for D66 turbos that do not have a ported housing.

06' F250 Harley Davidson Edition(Factory 2.5" lift)CCSB-blue sping kit, ARP, gaskets up, Driven Diesel Coolant Return, Sinister Diesel Coolant filter, Rotella ELC, SCT X4, 55gal Aluminum Fuel tank, B & W turnover. ...Hauling New RV's daily.
02' F250 687,000 miles towing...traded to friend for a boat
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post #8 of 41 (permalink) Old 09-01-2013, 02:47 PM
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Re: My E-Fuel Conversion and other things

looks good

-06 CCLB 6.0, studs, heads reworked, studs, dummy plugs, stand pipe, updated stc fitting, egr delete, 6.4 banjos, blue spring, New oil cooler, 40 FICM, stage 1 powermax, and Looney Wild, 4 inch exhaust
SOLD-1996 f250 4x4, ZF5 with BASB and 175/100s
-2002 F250 4x4, auto, ECLB, CAI, CCV mod, Dp-Tuner, air heater delete, 4"dp, billet 38R
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post #9 of 41 (permalink) Old 09-01-2013, 02:54 PM
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Re: My E-Fuel Conversion and other things

Quote:
Originally Posted by SledDogg View Post
Diesel site has a new Billet Wicked Wheel SPECIFICALLY for D66 turbos that do not have a ported housing.
I looked on their site but didn't see it

-06 CCLB 6.0, studs, heads reworked, studs, dummy plugs, stand pipe, updated stc fitting, egr delete, 6.4 banjos, blue spring, New oil cooler, 40 FICM, stage 1 powermax, and Looney Wild, 4 inch exhaust
SOLD-1996 f250 4x4, ZF5 with BASB and 175/100s
-2002 F250 4x4, auto, ECLB, CAI, CCV mod, Dp-Tuner, air heater delete, 4"dp, billet 38R
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post #10 of 41 (permalink) Old 09-01-2013, 03:52 PM
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Re: My E-Fuel Conversion and other things

Only thing I'd change is on the outlet side of the pump, I'd go with one of these.
Driven Diesel Fuel Pump Outlet Adapter


I had a teeny tiny drip on my with a compression fitting-bushing-(-6) jic. I've since swapped to the strictly diesel fitting and have had no more drip. Plus it looks much cleaner.

1997Single Cab Dually
S366 w/Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s,
Corbeau seats w 08 console, 19.5s, Black Interior with swede headliner and visors,
Custom badges, Flight Fab/DIY traction bars.

2012 CCSB F250 Ultimate Lariat.
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