Long Travel 302 swap
#77
05-07-2015
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05-13-2015
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05-19-2015
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05-26-2015
#85
05-26-2015
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So I thought the fuel pressure regulator on these explorers was in the tank with the fuel pump? But it looks like there's an FPR on the fuel rail as well. What's the difference between the two?
Thinking about swapping the one on the fuel injector rail because it's pretty gunked up.
Thinking about swapping the one on the fuel injector rail because it's pretty gunked up.
The on-rail is a lower, nominal 2 bar regulator, the in-tank system is a higher, nominal 3.5 bar regulator. Call it 25-30 psi vs 45-50 psi.
The other obvious difference is the vacuum port on the external regulator that drops fuel pressure under high vacuum. That mechanical reduction in fuel at low demand is replaced by logic in the PCM on the high pressure systems.
The std 19 lbs low pressure injectors will dump too much fuel at the higher fuel pressures.
Probably have 3 options:
Convert to a low pressure system by removing the in-tank FPR and plumbing in a return hose from the engine to the return at the fuel filter.
Find a 2 bar fpr that fits the socket in the tank and moving to a return-less fuel rail.
Dropping the injector's down a couple sizes should also get the fuel flow close enough for the PCM to manage. The OEM low pressure injector is rated at 19 lbs at 35 psi, you'd need to find an injector that would deliver 19 lbs at 55/60 psi adn then add a return-less fuel rail. -- probably the most costly and riskiest option.
#86
05-27-2015
The "big" difference is in the regulated pressure:
The on-rail is a lower, nominal 2 bar regulator, the in-tank system is a higher, nominal 3.5 bar regulator. Call it 25-30 psi vs 45-50 psi.
The other obvious difference is the vacuum port on the external regulator that drops fuel pressure under high vacuum. That mechanical reduction in fuel at low demand is replaced by logic in the PCM on the high pressure systems.
The std 19 lbs low pressure injectors will dump too much fuel at the higher fuel pressures.
Probably have 3 options:
Convert to a low pressure system by removing the in-tank FPR and plumbing in a return hose from the engine to the return at the fuel filter.
Find a 2 bar fpr that fits the socket in the tank and moving to a return-less fuel rail.
Dropping the injector's down a couple sizes should also get the fuel flow close enough for the PCM to manage. The OEM low pressure injector is rated at 19 lbs at 35 psi, you'd need to find an injector that would deliver 19 lbs at 55/60 psi adn then add a return-less fuel rail. -- probably the most costly and riskiest option.
The on-rail is a lower, nominal 2 bar regulator, the in-tank system is a higher, nominal 3.5 bar regulator. Call it 25-30 psi vs 45-50 psi.
The other obvious difference is the vacuum port on the external regulator that drops fuel pressure under high vacuum. That mechanical reduction in fuel at low demand is replaced by logic in the PCM on the high pressure systems.
The std 19 lbs low pressure injectors will dump too much fuel at the higher fuel pressures.
Probably have 3 options:
Convert to a low pressure system by removing the in-tank FPR and plumbing in a return hose from the engine to the return at the fuel filter.
Find a 2 bar fpr that fits the socket in the tank and moving to a return-less fuel rail.
Dropping the injector's down a couple sizes should also get the fuel flow close enough for the PCM to manage. The OEM low pressure injector is rated at 19 lbs at 35 psi, you'd need to find an injector that would deliver 19 lbs at 55/60 psi adn then add a return-less fuel rail. -- probably the most costly and riskiest option.
I'm also upgrading to 30lbs injectors because of the stroker kit. 19 just won't cut it, and 24 is maxed out. 30's should give it just what it needs with the right tune.
Does all this sound like it will work?
#87
05-27-2015
Join Date: Jan 2014
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So perhaps a larger MAF and throttle body too?
Yea, from what I've read, the 19 lbs injectors are running out of volume with even a mildly tweaked 302. With the stroker kit and some deep breathing in the heads and intake, the 24's will probably max out so I see the need for the 30's.
Adapting the fuel system is pretty easy. I used the front chunk of the doner Expo's fuel return line to get back to the fuel filter and then married the Expo return to the Ranger's.
One less than intuitive thing, on the Ranger filter, the middle nipple on the back of the filter is the return to the FPR in the tank, the smaller, offset nipple is the supply.
To add even more non-intuitive visuals is the OEM Expo filter supply nipple is the same size as the Ranger return line, but not the Ranger supply line!
A pair of fuel line couplers allowed me to swap the ends on the two lines and make it "plug and play".
Yea, from what I've read, the 19 lbs injectors are running out of volume with even a mildly tweaked 302. With the stroker kit and some deep breathing in the heads and intake, the 24's will probably max out so I see the need for the 30's.
Adapting the fuel system is pretty easy. I used the front chunk of the doner Expo's fuel return line to get back to the fuel filter and then married the Expo return to the Ranger's.
One less than intuitive thing, on the Ranger filter, the middle nipple on the back of the filter is the return to the FPR in the tank, the smaller, offset nipple is the supply.
To add even more non-intuitive visuals is the OEM Expo filter supply nipple is the same size as the Ranger return line, but not the Ranger supply line!
A pair of fuel line couplers allowed me to swap the ends on the two lines and make it "plug and play".
#88
05-27-2015
So perhaps a larger MAF and throttle body too?
Yea, from what I've read, the 19 lbs injectors are running out of volume with even a mildly tweaked 302. With the stroker kit and some deep breathing in the heads and intake, the 24's will probably max out so I see the need for the 30's.
Adapting the fuel system is pretty easy. I used the front chunk of the doner Expo's fuel return line to get back to the fuel filter and then married the Expo return to the Ranger's.
One less than intuitive thing, on the Ranger filter, the middle nipple on the back of the filter is the return to the FPR in the tank, the smaller, offset nipple is the supply.
To add even more non-intuitive visuals is the OEM Expo filter supply nipple is the same size as the Ranger return line, but not the Ranger supply line!
A pair of fuel line couplers allowed me to swap the ends on the two lines and make it "plug and play".
Yea, from what I've read, the 19 lbs injectors are running out of volume with even a mildly tweaked 302. With the stroker kit and some deep breathing in the heads and intake, the 24's will probably max out so I see the need for the 30's.
Adapting the fuel system is pretty easy. I used the front chunk of the doner Expo's fuel return line to get back to the fuel filter and then married the Expo return to the Ranger's.
One less than intuitive thing, on the Ranger filter, the middle nipple on the back of the filter is the return to the FPR in the tank, the smaller, offset nipple is the supply.
To add even more non-intuitive visuals is the OEM Expo filter supply nipple is the same size as the Ranger return line, but not the Ranger supply line!
A pair of fuel line couplers allowed me to swap the ends on the two lines and make it "plug and play".
From what I've read the explorer throttle body is plenty, and as long as I have a MAF the pulse can be changed for the 30lbs injectors with the tune I will get once everything starts up.
I'll just remove the bed like I normally do to access the fuel pump, and take that in tank regulator out. The pump is still fairly new, swapped it out about 5k ago with a new motor craft pump. I hope the adjustable FPR is easy to adjust
You said you had set yours closer to 40-45psi?
#89
05-27-2015
Also couple other questions for you guys:
Do you happen to know the output of the stock fuel pump? Will it be okay for these 30lb injectors or is that something I need to upgrade too?
The 97 explorer motor came with an oil cooler, can I keep that? Will it fit? Or do I need to remove it and get an adapter?
Do you happen to know the output of the stock fuel pump? Will it be okay for these 30lb injectors or is that something I need to upgrade too?
The 97 explorer motor came with an oil cooler, can I keep that? Will it fit? Or do I need to remove it and get an adapter?
Last edited by Prerunner-Ranger; 05-27-2015 at 10:26 PM.
#91
05-28-2015
Join Date: Jan 2014
Location: Tampa, Florida
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Looking good!
Won't be long until it's ready to box up and ship my way -- I promise I'll let you know how well it runs!
Not scientific, but I think the flow rate on your OEM fuel pump is "not enough". Think I'd be moving to a high flow pump at the same time you're pulling the FPR out of the tank.
But, YES, the OEM oil cooler fits fine. Finding the right size o-rings to seal it only took a quick trip to a local shop for me. The only "difficult" bit is that short length of hose between the cooler and water pump. Nor sure it's available as it's own part anywhere. But, a friendly auto parts house should not mind a bit of wandering the racks looking for a hose with a similar bend/size to adapt.
One nice thing about the oil cooler, it's got that drip rail under the filter to guide oil spills away from the cross member. Keeps oil changes pretty darn neat and clean.
Won't be long until it's ready to box up and ship my way -- I promise I'll let you know how well it runs!
Not scientific, but I think the flow rate on your OEM fuel pump is "not enough". Think I'd be moving to a high flow pump at the same time you're pulling the FPR out of the tank.
But, YES, the OEM oil cooler fits fine. Finding the right size o-rings to seal it only took a quick trip to a local shop for me. The only "difficult" bit is that short length of hose between the cooler and water pump. Nor sure it's available as it's own part anywhere. But, a friendly auto parts house should not mind a bit of wandering the racks looking for a hose with a similar bend/size to adapt.
One nice thing about the oil cooler, it's got that drip rail under the filter to guide oil spills away from the cross member. Keeps oil changes pretty darn neat and clean.
#92
05-28-2015
#93
06-09-2015
#95
07-07-2015
#96
07-12-2015
#97
07-27-2015
