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1995 7.3 Van intercooler addition questions

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1995 7.3 Van intercooler addition questions

  #1  
Old 01-10-2019, 06:24 PM
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1995 7.3 Van intercooler addition questions

Doing research on adding an intercooler to my 1995 7.3 Van, I'm trying to use mostly factory parts (the only things I've purchased so far is a used 1998-99 ford spider and used aftermarket intercooler).

Will the oem Ford spider work with my '95's mechanical lift pump?

Clearing out the lifter valley of the oem Ford stuff, mechanical lift pump, fuel bowl (and it's integral regulator), from what I can tell gets really involved and expensive.

I need to retain my dual tanks and selector valve, which doesn't seem to accommodate the aftermarket regulator system fuel/air return. It can all be fixed with $$$ I guess, like $1500-$1800 to re-do the entire fuel system (Swamps, AirDogII, others), rig up a tank-to-tank transfer pump.

I've read about removing the entrained air bubbles, quieting down the idle, make the fuel pressure adjustable, all of the benefits from aftermaket systems, but a guy could really get carried away.

But I'm not after 450hp, just a modest intercooler upgrade, and cleaning up some of the valley leaks.

My 95 has a mechanical lift pump, which might be in the way of the using oem 1998 spider (I think Ford changed to the Bosch electric pump when they intercooled the 7.3) .

If the stock 1995 mechanical lift pump can not be used with the 1998-1999 oem spider, I'm hoping to buy a block off plate, and use a Bosch electric fuel pump from a 1999 and later 7.3 truck.

Do I really have to delete the fuel bowl?

Am I correct in saying that moving the filters and pump down to the frame rail requires an aftermarket return regulator set up?

What if I leave most of my 1995 fuel system stock, only replacing the 'in the way' mechanical lift pump with an electric one?

If I am stuck with replacing the mechanical pump with Bosch electric pump, do I need to regulate the fuel down in pressure and add a return leg?

Any help would be greatly appreciated!
 
  #2  
Old 01-10-2019, 07:06 PM
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I think the van is the same enough as the pickup to tell you this. If you for sure have an early 99 spider (has the 2 3/8 ports to the intake, not 3 inch) you don't need to upgrade the fuel system. Stock pump is not in the way. You can put the spider in, build/mount pipes and IC and go.
 
  #3  
Old 01-10-2019, 07:42 PM
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No reason to spend $2000 on an efuel kit.

https://www.ford-trucks.com/forums/1...purchased.html
 
  #4  
Old 01-11-2019, 11:43 AM
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Originally Posted by 427 fordman View Post
I think the van is the same enough as the pickup to tell you this. If you for sure have an early 99 spider (has the 2 3/8 ports to the intake, not 3 inch) you don't need to upgrade the fuel system...
Yes, I'm certain the spider is a '98-early '99, known as an 'e99' on the forums. I patiently looked long and hard for one (that wasn't $325 'buy it now' price on ebay). As near as I can tell, most everything in the '95 7.3 van valley is the same as '95 7.3 truck.

The Craigslist Spyder guy threw in a pair of silicon stepped boots to go with it, that fit my factory plenums and the spyder.

Originally Posted by 427 fordman View Post
Stock pump is not in the way. You can put the spider in, build/mount pipes and IC and go.
That's what I really needed to know, and really good news fordman! Thanks!

 
  #5  
Old 01-11-2019, 10:55 PM
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If you have to use reducing boots then it’s not a e99 spider
 
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Old 01-11-2019, 11:50 PM
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Originally Posted by fordpride View Post
If you have to use reducing boots then itís not a e99 spider
Didnt the e99 from factory use reducer boots?!?!? I'm pretty sure they did tho I have never owned one.
 
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Old 01-12-2019, 08:12 AM
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  #8  
Old 01-12-2019, 08:14 AM
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Originally Posted by fordman67 View Post
Didnt the e99 from factory use reducer boots?!?!? I'm pretty sure they did tho I have never owned one.
youíre correct, my apologies
 
  #9  
Old 01-12-2019, 11:16 AM
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Originally Posted by fordpride View Post
If you have to use reducing boots then it’s not a e99 spider
Thanks for taking the time to post the pictures w/measurements and helping me out:

My craigslist spider has 2-3/8" plenum outlets, 3" turbo flange, making it an e99, correct?

The guy gave me a pair of ford plenums from the same engine as the spider, which turn out to have the same inlet tube diameter as the ones on the van. He told me all of it, the spider, stepped boots, clamps, and plenums are all off the same 1998 he's parting out. It all fits together on the bench. So long as the spider's outlet "Y" will straddle the stock '95 lift pump, I think we're good.

The reason all of this is important is because I'm trying to do this upgrade in stages and sort of on the cheap. I'm going after the leaks, first. Oil, fuel, exhaust up pipes, the EBP line this morning. As I delve into repairing leaks (from a few of the 27 different high and low pressure oil and fuel connections) I'm learning how the Ford stuff is supposed to work at the same time.

At the same time I'm gathering up parts for the IC upgrade. I'll need to relocate several items in the van's engine bay. Oil fill tube and dipsticks might need to move, the dual underhood batteries need to move to the frame rails (I bought some 2001 Ford Van frame mount battery boxes), all to make room for the custom IC tubes I'll make. Eating the elephant one bite at a time. You think I should change my 4x4 Diesel camper van's name from 'The Beast', to 'Jumbo the Elephant'?

I could be wrong, but with ULSD and biodiesel compatible viton o-rings now available to retrofit the Ford fuel bowl with for instance, 'throwing out the baby with the bathwater' and removing the Ford/IH fuel system just doesn't seem necessary. Mine works, it just dribbles and stinks like Diesel. Leaks are fixable.
 
  #10  
Old 01-12-2019, 11:28 AM
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As long as you are not upgrading injectors, turbo, etc. it isn't necessary to change the fuel system. If you plan on upgrading injectors in the future, dont throw money away at the stock system. If you would have to replace something like the fuel bowl I would for switch to electric fuel now as that is expensive unless you find a good used one.

if your spider measures 2 3/8 you are good.
 
  #11  
Old 01-12-2019, 02:10 PM
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Originally Posted by fordpride View Post

youíre correct, my apologies
Aww heck Mike, it's all good. Just making sure I wasn't wrong as much as anything lol.
 


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