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2003 Ford F-250: Project Outcast Part 7

More Fuel For The Fire

Text By , Photography by , Strictly Diesel

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.

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.

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.

*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
1451 Engineer St Suite B
Vista
CA  92081
760-598-2478
http://www.cfmplus.com/
Strictly Diesel
7333 E Butherus Dr
Building A-100
Scottsdale
AZ  85260
480-922-8769
www.strictlydiesel.com
Elite Diesel Engineering
85 N. Silicon Dr.
Pueblo West
CO  81007
866-631-8518
http://www.elitedieseleng.com
Randall's Performance and Accessory
RR 1 Box 134
Gladstone
IL  61437
309-627-2500
www.randallsperf.com
Fass
4302 E Congress Ave
Spokane
WA  99223
866-379-8685
www.fassride.com
Fuelab
826-A Morton Court
Litchfield
IL  62056
1-217-324-3737
http://www.fuelab.com/
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16 comments
Tony Bland
Tony Bland

Is it best to replace the EGR cooler or just delete it on a 2005 6.0??

Scott Brown
Scott Brown

Heck I'm over 500hp with 175/75 injectors and a MTW Hybrid turbo

Scott Brown
Scott Brown

Mad Turbo Werks stage 3 and good tuning would put you well over 500hp. We made 534hp on a stock charger, 190cc/70% nozzle and stock fuel system.

Ben 'Bendels' Morgan
Ben 'Bendels' Morgan

185 are plenty big sticks. The power max is a joke in my opinion. Runs out of air. Might as well keep stock turbo because that's all a powermax is is a glorified stock turbo.

Harris On Ford
Harris On Ford

Quit throwing fuel to it! Stick with the 185s and get a billet wheel for the powermax and some good tuning

Brady Dye
Brady Dye

It should have a good diesel in it. Perhaps a Cummins like a DODGE!!!!!!!! Maybe. GUTS, GLORY, RAM!!!!!!!!!!!!!!!!!!!!!!!

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