I have the Hutch mod with 3/8" diesel rated hose to my prepump filter. 3/8" out of the filter to my New OEM Bosch pump. Out of the pump is all stock except for a FRx. I think a full regulated return will still be needed. The fuel pump I just removed is not factory like I thought. I believe it is an Airtex mabe? I haven't started it yet but I turned the key and the pressure came up, so it works so far.

 

Scott you seem to have the inside line on testing results on diesel fuel pump and was wondering if you share with us what made the top 5 diesel fuel pumps for the 7.3 PSD. And who tested them and what were they tested for?

 

I've seen the regulated return on 2000ca250's truck and it looks like it has a snubber tank. A snubber tank is a kind of reserve tank (very small) to give a little extra fuel to the line for a second or two, while the pump spools up. That will work, as long as the pump can keep up with full demand. Lowering the FRx spring will also work.

I know many will spin their heads and vomit, screaming "Fuel pressure is power and a weaker spring is less power!", but the HUEU system changed the rules. 10, 20, or 30 PSI more fuel pressure above the minimum 45 PSI is a joke compared to the 21,000 peak PSI that hits the nozzles. The fuel pump just needs that minimum 45 PSI to refill the injector reservoir before the next injector activation. I'm not saying "run the pump at 45", I'm saying don't let the fuel pressure stay below 45 PSI at WOT.

 

BadDogKuzz, The top 5 diesel fuel pumps tested for Ford's initial sourcing consideration for the 7.3L application (1998-03 vehicles: F-Series F250 & up, Econ Van, & Excursion). Walbro, Bosch, Nippon Denso, Ford (Rawsonville Plant), & Delphi (but Delphi was dropped from the list due to some financial concerns at the time and replaced by Visteon Corp).

The "final" testing was conducted at the Ford Engineering Lab, as well as each supplier being responsible to provide their own testing data from the Engineering Specification (ES) requirements. The testing was a 28 day continuous performance test, which for simple terms was a shake, rattle & roll test under pressure, along with using a salt spray to each part to reflect harsh conditions. The salt spray is just that, water and salt sprayed to each part for the duration of the 28 day test. The testing environment included a "high-temp and low-temp" condition as well. After the first 28 day testing, then there would be another 28 day testing using the same conditons/requirements but this test was a "start-stop" test, meaning the pumps would be starting and stopping at different intervals while being under the above conditions (shake, rattle, roll--salt spay with using high and low temps). This testing was known as the "ES durability & performance test".

I haven't pull all of the test results from each potential supplier but the top 2 diesel fuel pump performers were 1) Bosch and 2) Walbro...It wasn't even close for the top spot. Bosch out performed in ALL category's and was selected/awarded the business for this application.

But in keeping apples to apples, then the Ford Program manager had to review the total package=UNIT COST...While Bosch was also at the top of this category as well, there was a "long-term" agreement made between Ford and Bosch, and the sourcing decision was made.

 

This adds chorus to the drums I've been beating. I looked at the design and knew the Bosch was the one. Just one caveat to all of this: The reducion in the lubricity of the ULSD fuel has an impact on even my revered Bosch. Fuel additive will be in every single tank as long as Stinky is rolling under my butt.

 

Do you still have ULSD where you live? I have not been able to get anything other than (bio 5-15% is what the pump says) where I live.

 

I've been told we're 5%, and yes... that does help with lubricity. I haven't even looked into the Cetane factor of bio - now you got me wondering.