1999-2002 7.3 PSD
From WVO Designs Wiki
In 1999, an air to air intercooler was added. The intercooler cooled the charged air from the turbo making it denser. The cooler, denser air would increase the horsepower potential of the engine, while also reducing exhaust gas temperatures (EGTs). The turbine housing was changed to a .84 A/R housing and a wastegate was added. The "single shot" HEUI injectors were upgraded to "split shot" injectors. With larger injectors, the HPOP was advanced to 17º to increase fuel pressures. The 7.3L DI Power Stroke was in production up until 2003 when it was replaced by the 6.0L. In 2003 Ford Motor Company split the year, early 2003 the 7.3 DI was available, and the later part of the year got the new 6.0L. This is known to be the longest lasting and most reliable powerstroke engine.
Contents |
Major Conversion Component Sourcing
Valves - 3 Port Solenoid Valves - Purchase Purchase here
Heated Pickup for Tank - Raw Power Hot Stick- Purchase here
Fuel Pump - Raw Power WVO Fuel Pump - here
Tech
Fuel System Pressure 1999 47 to 55psi 2000-2003 40 to 60psi
Fuel Fittings on head 1/8"NPT
Two Tank Automatic Switching
Preamble
I am pleased to present you the “Raw Power” Ford PSD design for 1999-2003 Power Stroke. I have done my best to present correct and accurate information however mistakes happen and I give no guarantee or warranty; you get what you pay for.
As an engineer of few words, I am going to lean heavily on the “pictures are worth a thousand words” concept. Match up the balloons with the Bill of Material at the end of this document and you should have everything necessary.
Pictures
Tank
F350 had pass through holes at the front of the box, you may need to drill your own. Be sure to add some kind of edge protector so as not to have your hoses cut by the edge of the hole.
Pump and Filter
Ball valve was added so that you can shut off the fuel system when changing filter.
Engine
Veggie lines split to left rear and right front head. In order to access front right port, you will need to remove A/C Compressor mount and serpentine belt.
Left rear veggie line, this one is probably the most accessible but still a pain in the ass to get to.
Right rear diesel fuel line with installed check valve. This one is a royal pain to get to, remove turbo y-pipe and take your time.
Left front and right rear diesel fuel lines require 1/8” check valves. Remove alternator casting and serpentine belt for access to left front and turbo for right rear.
Fuel System Schematic.
Fuel System Schematic.
Electrical Schematic for Automatic Controller.
Electrical
First, I want to say that I am NOT an electrical engineer. The components and concepts I used are quite basic and possibly leave a lot of room for improvement.
Basic Advise
- Get yourself an “automatic wire stripper” it became my new favorite tool.
- For connections and splices under the vehicle use solder and a double wall heatshrink (the inner wall is a hot melt adhesive and seals the connection)
- Get a power tester that lights up to find your power sources. I used the radio power sources: Red: fused power, White: switched power, Black: Ground.
- Use wire loom to contain wire bundles for routing outside of cab
- Use zip ties to secure wire and loom anyplace possible.
- Don’t even think about using non fused power.
- Use 14Ga wire for switching and 12GA for the Fuel Pumps and Heater.
List Of Mechanical Parts
http://www.wvodesigns.com/index.php/Designs/View-category.html
| Item | Part Number | Description | Source | Qty | Cost Each | Ex Cost |
|---|---|---|---|---|---|---|
| 1 | 3490154 | VO Tank - 80GAL | Northern Tool | 1 | $450.00 | $450.00 |
| 2 | n/a | Hot Stick | WVO Designs | 1 | $150.00 | $150.00 |
| 3 | n/a | Raw Power Fuel Pump | WVO Designs | 1 | $445.00 | $445.00 |
| 4 | n/a | Donaldson Filter Head with 1/2"NPT Ports | 1 | $35.00 | $35.00 | |
| 5 | 7775K63 | Brass Spring-loaded Piston Check Valve, 3/8" Nptf Dryseal Male Connections, Viton Seat | McMaster Carr | 1 | $22.92 | $22.92 |
| 6 | 3454K23 | Tamper-resistant Non-adj Pressure Switch, 1/8" Npt Male, 65 Psi Actuation Point | McMaster Carr | 1 | $39.78 | $39.78 |
| 7 | 7876K68 | Delrin Solenoid Valve, Normally Closed, 18" Leads, 3/8" Npt Female,12 Vdc | McMaster Carr | 1 | $37.82 | $37.82 |
| 8 | 7768K61 | Brass Spring-loaded Piston Check Valve, 1/8" Npt Female X 1/8" Npt Male, Viton Seat | McMaster Carr | 2 | $9.43 | $9.43 |
| 9 | Existing | Diesel Filter | Stock | 0 | $0.00 | $0.00 |
| 10 | Existing | Diesel Pump | Stock | 0 | $0.00 | $0.00 |
| 11 | Existing | Diesel Tank | Stock | 0 | $0.00 | $0.00 |
| 12 | n/a | Custom Heat Exchanger Plate For the Pump With 5/8" Fittings | 1 | $100.00 | $100.00 | |
| 13 | n/a | Mounting Bracket for the DPP Pump | 1 | $50.00 | $50.00 | |
| 14 | AN-5127D | - 12vdc 200watt Hater Jacket | 1 | $75.00 | $75.00 | |
| 15 | @ | NAPA Gold Fuel Filter | Napa | 1 | $20.00 | $20.00 |
| 16 | 943-201 | Ball Valve, 3/8" NPTF Nickel-Plated Brass | Discount Hydrolic Hose | 2 | $8.55 | $17.10 |
| 17 | R14-04 | 3/16" SAE 100R14A Teflon (PTFE) Hose | Discount Hydrolic Hose | 5 | $1.81 | $9.05 |
| 18 | R14-06 | 5/16" SAE 100R14A Teflon (PTFE) Hose | Discount Hydrolic Hose | 25 | $2.33 | $58.25 |
| 19 | 63-190600-04 | Teflon Hose End - JIC Female Swivel, 1/4" | Discount Hydrolic Hose | 4 | $6.05 | $24.20 |
| 20 | 63-190600-06 | Teflon Hose End - JIC Female Swivel, 3/8" | Discount Hydrolic Hose | 8 | $7.72 | $61.76 |
| 21 | 6506-06-06 | 3/8" NPTF (F)x 3/8" JIC (F) | Discount Hydrolic Hose | 1 | $1.65 | $1.65 |
| 22 | 6505-06-06 | 3/8" NPTF (M)x 3/8" JIC (F) | Discount Hydrolic Hose | 4 | $1.26 | $5.04 |
| 23 | 6500-06-06 | 3/8" JIC 37° x 3/8" JIC 37° Fem. Swivel | Discount Hydrolic Hose | 2 | $1.32 | $2.64 |
| 24 | 6500-04-04 | 1/4" JIC 37° x 1/4" JIC 37° Fem. Swivel | Discount Hydrolic Hose | 2 | $1.33 | $2.66 |
| 25 | n/a | 1/4"ID Heater Hose | 5 | $0.20 | $1.00 | |
| 26 | n/a | 5/8"ID Heater Hose | Napa | 30 | $0.25 | $7.50 |
| 27 | 5406-06-02 | 3/8" Male x 1/8" Female NPTF (BUSHING) | Discount Hydrolic Hose | 1 | $0.44 | $0.44 |
| 28 | 102-1208C | 3/4" Hose x 1/2" Male Pipe | Discount Hydrolic Hose | 2 | $2.09 | $4.18 |
| 29 | 2404-06-08 | 3/8" JIC x 1/2" NPTF | Discount Hydrolic Hose | 5 | $0.82 | $4.10 |
| 30 | 2404-06-06 | 3/8" JIC x 3/8" NPTF | Discount Hydrolic Hose | 3 | $0.58 | $1.74 |
| 31 | 2404-06-04 | 3/8" JIC x 1/4" NPTF | Discount Hydrolic Hose | 1 | $0.35 | $0.35 |
| 32 | 2404-04-02 | 1/4" JIC x 1/8" NPTF | Discount Hydrolic Hose | 2 | $0.29 | $0.58 |
| 33 | n/a | 1/2" Nylon Lock Nut | Napa | 2 | $0.10 | $0.20 |
| 34 | 5602-06-06-06 | 3/8" x 3/8" x 3/8" NPTF | Discount Hydrolic Hose | 1 | $3.36 | $3.36 |
| 35 | 2603-06-06-06 | 3/8" x 3/8" x 3/8" JIC | Discount Hydrolic Hose | 2 | $1.50 | $3.00 |
| 36 | 2406-06-04 | 3/8" Female x 1/4" Male JIC | Discount Hydrolic Hose | 2 | $0.67 | $1.34 |
| $1,613.02 |
List Of Electrical Parts
| Item | Part Number | Description | Source | Qty | Cost Each | Ex Cost |
|---|---|---|---|---|---|---|
| B1 | n/a | Battery | Existing | n/a | n/a | $0.00 |
| B2 | n/a | Fuel Pump - Item 3 In fuel system | See Fuel System | n/a | n/a | $0.00 |
| B3 | n/a | Fuel Filter Heater - Item 14 in fuel system | See Fuel System | n/a | n/a | $0.00 |
| B4 | 7876K68 | Purge Solonoid - Item 7 in fuel system | See Fuel System | n/a | n/a | $0.00 |
| B5 | Existing | Engine Run Relay | Existing | n/a | n/a | $0.00 |
| B6 | Existing | Diesel Pump | Existing | n/a | n/a | $0.00 |
| S1 | TDTS3022A160RW | Temperature Switch, NO, 160F, 3/8"NPT | transducersdirect.com | 1 | $32.00 | $32.00 |
| S2 | HRPSD22TS | AAB Solid State Timer Relay- Trailing Edge Single Shot Adjustable | Atlantic Control Products | 1 | $40.56 | $40.56 |
| S3 | Purge Switch - Single Pole Single Throw - Momentary | Need Source | 1 | $10.00 | $10.00 | |
| S4 | Master Switch - Double Pole Single Throw | Need Source | 1 | $10.00 | $10.00 | |
| S5 | HRDB121 | AAB Solid State Timer Relay - Time Delay on Release Adjustable | Atlantic Control Products | 1 | $51.08 | $51.08 |
| S6 | 3454K23 | Pressure Switch - Item 6 in fuel system | See Fuel System | n/a | n/a | $0.00 |
| K1 | 9672K31 | 5 pin relay | McMaster Carr | 1 | $6.70 | $6.70 |
| K2 | 9672K31 | 5 pin relay | McMaster Carr | 1 | $6.70 | $6.70 |
| K3 | 9672K31 | 5 pin relay | McMaster Carr | 1 | $6.70 | $6.70 |
| K4 | n/a | Internal to S2 | n/a | n/a | n/a | $0.00 |
| K5 | n/a | Internal to S2 | n/a | n/a | n/a | $0.00 |
| K6 | 9672K31 | 5 pin relay | McMaster Carr | 1 | $6.70 | $6.70 |
| K7 | 9672K31 | 5 pin relay | McMaster Carr | 1 | $6.70 | $6.70 |
| D1 | 76-270 | Red LED | Radio Shack | 1 | $1.99 | $1.99 |
| D2 | 76-272 | Orange LED | Radio Shack | 1 | $1.99 | $1.99 |
| D3 | 76-271 | Green LED | Radio Shack | 1 | $1.99 | $1.99 |
| SUM($183.11) |
