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Fuel System Mods for E85

cbrtrx

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I think a properly designed 6 micron filter that has enough flow without excessive pressure drop would be a little large for an under the hood application. I'm sure you could physically fit one but it might not be very aesthetically pleasing.
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NightmareMoon

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@NightmareMoon did y’all install the gt350 line without dropping the tank?
thats what I was told, althought I’m not sure how. i can ask, although it might be the same procedure for freeing the noise pipe from the firewall (yank hard).
 

SheepDog

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I think a properly designed 6 micron filter that has enough flow without excessive pressure drop would be a little large for an under the hood application. I'm sure you could physically fit one but it might not be very aesthetically pleasing.
Honestly, they don't fit under the car very well either. I'm working on an aluminum cover that will tap into my jacking rail, and then use the OEM fastener points that the current plastic cover uses now. Basically a lil' baby skid plate. Having the filter in the engine bay is better anyway for ease of service.
 

cbrtrx

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Honestly, they don't fit under the car very well either. I'm working on an aluminum cover that will tap into my jacking rail, and then use the OEM fastener points that the current plastic cover uses now. Basically a lil' baby skid plate. Having the filter in the engine bay is better anyway for ease of service.
I wonder about fuel temp increase from having it in the bay as well. I think I'd would absorb some heat, it would be like the rails that get hot and keep heating up the fuel. It might be ok if used in a returnless setup though. I'd rather have it under the car. On my car under all the same conditions going from a full return system to a returnless dropped average fuel temps by about 30 degrees. Cooler fuel is more power.
 

KPM Fuel Systems

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Good stuff,

The lack of a fuel filter on the 800-1000 systems is a deterrent for a lot of buyers.

The second issue is that The Coyote platform can't get anywhere near 800 HP on pump gas, and since race gas here in the US is around $10 a gallon, everyone goes to E85.That being said, the 800-1000 modules won't support more than maybe 550-600 on E85? Really for this platform, the 1500 HP system is the minimum requirement for people to make 800+ wheel, which the Coyote will do fairly easily with a decent power adder.

Have you guys tested the 800-1000 systems with a BAP?
100% agree. Were are on it , and should be available in the next few months.

KPM800
Along with fuel support for extra power ,the main requirement for the KPM800 is for track enthusiasts experiencing fuel starvation on high speed LH sweepers/corners. They generally do not need to support extra power, however they require fuel retention for race tracks.
All the KPM modules have the ability over the factory module to retain a full bucket of fuel around race tracks.

KPM1000
Perfect sizing fuel delivery for most entry level supercharger upgrades.
1000fwhp on Pump gas / approx 750 rwhp
720fwhp on E85 / approx 540 rwhp

KPM1500
Higher levels of power requirements. Generally E85 usage
1500hp on Pump gas
1120fwhp on E85 / approx 840 rwhp

All the above levels of KPM Systems have the ability to be added on to should you upgrade your power levels.
We have ADD-ON kits to bring you all the way up to 2700HP!

I understand that voltage boosters are a proven popular aftermarket method of increasing fuel delivery.

We do not recommend voltage boosters due to the increased amperage created by ramping voltages to your fuel pump.
Our philosophy is to engineer a range of fuel systems that integrate with factory systems without compromising components and are rated for the intended power requirement.
Both the fuel pump and vehicle wiring and connectors are all rated at a maximum amperage. By boosting voltages it increases heat and the risk of component failure.
Also increased amperage's create increased heat transfer into the fuel.
Our aim is to keep the fuel as cool and dense as possible to achieve maximum sustainable power.
 

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Mikepol2

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Mikepol2

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Watched this video on the difference between return and returnless systems and maybe I'm missing something but I don't know why anyone would use a return system other than they haven't figured out the tune for a returnless system yet...

 

Unas2k5

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I wonder why @w
I have two cars running the dw400/jms bap on a Whipple with a 3” pulley, one with gt500 55# injectors even. Fuel pressure consistently in the 50’s. You have to make sure it’s getting 48% commanded lift pump dc and as @cbrtrx said, fuel rail upgrade is crucial unless it’s a Roush or Whipple that comes with them.
I wonder why @Wengerd Performance hasn’t responded to this. @engineermike I wish if all these tuners were as knowledgeable as you. I hate my current Lund tune! I wish if you were local. I’d drop my car off in a heartbeat.
 

mepawn

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I wonder why @w


I wonder why @Wengerd Performance hasn’t responded to this. @engineermike I wish if all these tuners were as knowledgeable as you. I hate my current Lund tune! I wish if you were local. I’d drop my car off in a heartbeat.
This whole thread has me curious now. Currently I have a fore triple fuel pump, aftermarket lines, fuel filter, and regulator. When it comes to complication of install, i personally dont find it hard at or complicated. Then again it was installed when I added a vmp supercharger. My system has been running for 4 years without issue. Granted i also built my car for drag racing specifically.

Personally I would never drive a fuel pump with a BAP. If we are talking about efficiency and thermal loading, a BAP overdrives the fuel pump past its intended voltage creating more heat and a potential failure point, just get a bigger pump and that eliminates this issue.

I do have to say though having the safety of the PCM for fueling would be nice but i have a gen 2 car and dont know if they have that capability compared to the gen 3.

Im also tuned by Lund and dont really have issues at all that were not caused by failing sensors or faulty parts, curious as to what issues you are running into.
 

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engineermike

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...I would never drive a fuel pump with a BAP. If we are talking about efficiency and thermal loading, a BAP overdrives the fuel pump past its intended voltage creating more heat and a potential failure point...
DW actually rates the DW400 to run up to 20 volts, and the JMS 22v BAP only supplies 20 volts at the pump after efficiency losses and voltage drop. DW does give lower and higher voltage limits depending on which pump it is. For instance, they explicitly say to not run the DW810 over 14.5 volts but the DW440 is good up to 26 volts. During bench testing, we ran a DW400 at 22 volts for minutes at a time and it showed no signs of distress.

Another thing is that, if set up properly, running a BAP does not actually run high voltage at the pump all the time. Even a constant voltage BAP just boosts voltage supplied to the FPDM, which then cuts it down unless max flow is needed. Most of the time the pump is only receiving 3-5 volts even with a constant 18 or 22v supplied by a BAP.

I do have to say though having the safety of the PCM for fueling would be nice but i have a gen 2 car and dont know if they have that capability compared to the gen 3.
The gen2 doesn't have a lift pressure sensor like the gen3, so on the whole it's probably not as safe to run closer to the edge on fuel systems. Basically, if fuel pressure drops it would only see it in the STFT and then add IPW. The gen2 does have the ability to cut throttle if the IPW hits the limit, unless the tuner unwittingly defeats it.
 

mepawn

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DW actually rates the DW400 to run up to 20 volts, and the JMS 22v BAP only supplies 20 volts at the pump after efficiency losses and voltage drop. DW does give lower and higher voltage limits depending on which pump it is. For instance, they explicitly say to not run the DW810 over 14.5 volts but the DW440 is good up to 26 volts. During bench testing, we ran a DW400 at 22 volts for minutes at a time and it showed no signs of distress.

Another thing is that, if set up properly, running a BAP does not actually run high voltage at the pump all the time. Even a constant voltage BAP just boosts voltage supplied to the FPDM, which then cuts it down unless max flow is needed. Most of the time the pump is only receiving 3-5 volts even with a constant 18 or 22v supplied by a BAP.



The gen2 doesn't have a lift pressure sensor like the gen3, so on the whole it's probably not as safe to run closer to the edge on fuel systems. Basically, if fuel pressure drops it would only see it in the STFT and then add IPW. The gen2 does have the ability to cut throttle if the IPW hits the limit, unless the tuner unwittingly defeats it.
Interesting, i thought most dialed in their fuel pumps at 16 volts and then rated for 14.5. In that case if it was designed for it I wouldnt mind. Although id probably still have a secondary pump (so im not stranded if the primary dies). This is where id love to dive into more tuning and electrical controls but admittedly i will not do any of that testing my current expensive car. Want to get a cheap vehicle that has a swap in it with a Holley or something.

I guess in regards to the gen 2, overdoing it with the pumps i have, triple Walbro 525s,
is definitely safer rather than sorry as the STFT are slightly delayed with them being readings from the O2 sensors.

Now another question. When you get into boost, how does the returnless style system see this and increase the base pressure of the fuel in conjunction with the boost? Say base pressure is 55psi and then at WOT you are at 75psi for 20psi of boost. If it is able to reference boost and increase pressure, would the command PWM voltage to the pump pick up quick enough to prevent a temporary lean condition?
 

engineermike

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Now another question. When you get into boost, how does the returnless style system see this and increase the base pressure of the fuel in conjunction with the boost? Say base pressure is 55psi and then at WOT you are at 75psi for 20psi of boost. If it is able to reference boost and increase pressure, would the command PWM voltage to the pump pick up quick enough to prevent a temporary lean condition?
It's really interesting how this works on the gen3. There is a feed-forward table in the tuning that uses desired pressure and predicted fuel flow to look up a "voltage" to supply to the pump. Basically, the logic knows the desired air flow and fuel flow and can modulate the throttle and ramp up pump voltage in unison based on future state. This voltage is converted to a duty cycle commanded to the FPDM, which then sends PWM power to the pump. Then, it measures the rail pressure and there is a PID feedback control loop to correct the supply voltage further if the desired and actual fuel pressures don't match. There is also a KAM learning component here, where if it consistently has to add or subtract from the feed-forward table voltage, it will store and include that in the commands in the future.

The gen2 has the same feed-forward table, just without the feedback control and KAM learning.

Just recently, I decided to wire my 22v BAP to stay in 22v mode 100% of the time and use the FPDM to do all of the modulation. It's not generally a good idea to have multiple entities (PCM + BAP) trying to control one thing. I just disabled the feedback loop and tuned the feed-forward table until rail pressure consistently stayed where I wanted it. Then, once the feedback was reactivated, the pressure tracked remarkably well.
 

mepawn

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It's really interesting how this works on the gen3. There is a feed-forward table in the tuning that uses desired pressure and predicted fuel flow to look up a "voltage" to supply to the pump. Basically, the logic knows the desired air flow and fuel flow and can modulate the throttle and ramp up pump voltage in unison based on future state. This voltage is converted to a duty cycle commanded to the FPDM, which then sends PWM power to the pump. Then, it measures the rail pressure and there is a PID feedback control loop to correct the supply voltage further if the desired and actual fuel pressures don't match. There is also a KAM learning component here, where if it consistently has to add or subtract from the feed-forward table voltage, it will store and include that in the commands in the future.

The gen2 has the same feed-forward table, just without the feedback control and KAM learning.

Just recently, I decided to wire my 22v BAP to stay in 22v mode 100% of the time and use the FPDM to do all of the modulation. It's not generally a good idea to have multiple entities (PCM + BAP) trying to control one thing. I just disabled the feedback loop and tuned the feed-forward table until rail pressure consistently stayed where I wanted it. Then, once the feedback was reactivated, the pressure tracked remarkably well.
AHHHH so it is anticipating the future rail pressure based on the MAF and throttle position then using the rail pressure measurement as a verification/additionally safety and then the learning curve will help reinforce the additional full under the boost conditions. That makes sense as it will certainly help prevent the potential "lean condition" on the hit.

Do you have the fuel pressure ramp up when in boost? I would imagine you do/ tuned it into the vehicle as youre going to want that extra pressure to compensate for "boost pressure" in the cylinders that would be fighting against the fuel injection in effect creating less injection pressure from the injectors.
 

engineermike

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AHHHH so it is anticipating the future rail pressure based on the MAF and throttle position then using the rail pressure measurement as a verification/additionally safety and then the learning curve will help reinforce the additional full under the boost conditions. That makes sense as it will certainly help prevent the potential "lean condition" on the hit.
Think more on the predictive side of things. The logic interprets pedal input as a torque request. It converts that to load, to airflow, to fuel flow. It knows if it opens the throttle x degrees under these conditions then it gets y flow. It also knows if it sends x volts to the pump then it gets y flow. So it sends them all (plus ipw, cams, timing) to future state at once then uses PID feedback to fine tune once everything gets there.

Do you have the fuel pressure ramp up when in boost? I would imagine you do/ tuned it into the vehicle as youre going to want that extra pressure to compensate for "boost pressure" in the cylinders that would be fighting against the fuel injection in effect creating less injection pressure from the injectors.
The stock tune is set up to run 58 - 65 psi at idle and cruise and 72 psi at high fuel demand. When pushing the fuel system to the limits, you're actually balancing pump and injector flow. The injectors flow more at high pressure but the pump flows less. Basically everything I've done requires full voltage to the pump at WOT and the pressure is what it is, usually 50-65 psi.
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