2008 Ford F250 - Project KR, Part III
The Ford gets an engine programmer, air filtration system, and exhaust
From the October, 2011 issue of 8-Lug
Author: Chuck Eickhoff
Photography: Chuck Eickhoff
The Edge Evolution, installation...
The Edge Evolution, installation pod, and data link cable are all you need to add up to 100 hp to your truck.
Last issue, Project KR got a lift kit and larger tires installed to give it the stance we wanted. With the new look, though, we lost 2 mpg in fuel economy due to increased airflow resistance caused by the lift and larger tires.
With our Ford F-250 diesel there are several ways to increase fuel economy. The question is: Which way best fits our requirements?
John Hamlin, owner of Diesel Performance Shops in Van Nuys, California, has a wealth of knowledge on the subject. For our application, he recommended the Edge Evolution programmer for its ease of installation, flexibility, and performance. This programmer offers four levels of tune above stock. Level 1 adds 25 hp and 55 lb-ft of torque. Level 2 adds 40 hp and 75 lb-ft of torque. Level 3 adds 60 hp and 130 lb-ft of torque. Level 4 adds 100 hp and 200 lb-ft of torque.
The Evolution also monitors (via the OBDII port) exhaust gas temperature (EGT) and 11 other vital engine functions, including the transmission fluid temperature. No drilling is required for sensors nor is any intrusion of the factory wiring necessary. In the digital display mode, there is a maximum of four functions shown at any one time, but you get to choose from 12 available options.
We began by removing the weatherstripping...
We began by removing the weatherstripping near the A-pillar on the left side of the dashboard. Next, we pulled off the access panel.
With the programmer chosen, we needed to address the intake and exhaust. AFE offers both air cleaner upgrades and DPF-back exhaust systems. For the intake, a reusable replacement filter is offered (part number 10-10107) that does not require any modification to the factory air cleaner housing. If a complete cold-air intake system is your desire, AFE has part number 54-11262, which replaces the factory airbox. With increased airflow from the intake side, we turned our attention to the exhaust system. Part number 49-43006 is a DPF-back system, manufactured in 409 stainless steel using tubes that are larger diameter than stock tubes and mandrel-bent. John recommends not increasing power beyond 100 hp and 200 lb-ft of torque with the truck in stock form. The Edge Evolution also has different levels of tunes, and all of them protect the truck—no matter how it’s being used. Economy (Level 1) is for daily driving and is tuned for optimum fuel economy. Towing (Level 2) is intended for heavy loads, like a boat or camper. This setting provides improved transmission shifting along with modified fuel timing and fuel injection strategies. The goal here is to improve fuel economy as well as provide added horsepower and torque. Race (Level 3) is what the name suggests and is not recommended for towing. The transmission strategy is modified by providing quicker, firmer shifts. Extreme (Level 4) should also not be used when towing. This is the highest performance setting on the Evolution, with the fuel injection and fuel timing strategies aggressively tuned to extract maximum performance without sacrificing driveability or durability. The transmission strategy is modified, providing quicker, firmer shifts.
With the data cable for the...
With the data cable for the OBDII in hand, we made sure the ignition key was in the OFF position and started to route the cable.
We fed the end that connects...
We fed the end that connects to the Evolution up behind the dash and out by the seal trim. We wanted to have the Evolution connection come out by the top of the dash by the A-pillar and allow approximately 4 to 6 inches of cable.
We wanted to check the cable...
We wanted to check the cable length for proper fit to the OBDII port, so John plugged it in to make sure he had the correct length during installation.
With the data cable end for...
With the data cable end for the programmer sticking out of the top of the dash, we reinstalled the access panel.
With the data cable sticking...
With the data cable sticking out the top of the dash, we positioned the pod.
Sliding the Evolution into...
Sliding the Evolution into the pod, we made sure the cable fit without restrictions.
After being pressed into place,...
After being pressed into place, the rubber grommet gives a secure and flush mount.
Any excess cable may be placed...
Any excess cable may be placed behind the Evolution in the pod and/or pulled back through the dash to eliminate slack. We were sure to secure excess cable underneath the dash with the supplied cable ties. Then we checked for proper pedal action without cable interference and connected the device to the OBDII port.
The Evolution is user friendly...
The Evolution is user friendly and John makes it look so easy to program. The device walks you through the process, and John gave us suggestions regarding options and parameters as he set our unit up. For the four digital displays, we chose engine temperature, transmission temperature, exhaust gas temperature (EGT), and speedometer.
John typically sees the highest gains in fuel economy when using Level 4, but only if driven with moderation. If you are constantly under hard acceleration, Level 1 is best for fuel economy and extending the life of the vehicle. Driving Project KR in stock trim on the same route from the San Fernando Valley to Kernville, California, several times before the lift, confirmed an average of 16.8 mpg roundtrip. After we installed the lift, tires, and wheels—driving the same route—we dropped to 14.6 mpg for a loss of 2.2 mpg. With the AFE DPF-back system, air filtration system, and the Edge Evolution installed, we made the same run from the San Fernando Valley to Kernville. Using Level 4, we jumped to 16.9 mpg (a 2.3-mpg increase), giving us back our lost fuel economy from the lift and tires. Remember, there is an added increase in engine power. The feeling you get when you quickly pass the car next to you up a grade in an 8,500-pound truck is fantastic—as John describes it: “the big-block feeling.”
Here’s a look at the AFE stainless...
Here’s a look at the AFE stainless steel DPF-back exhaust system and replacement air filter ready for installation.
The replacement AFE filter...
The replacement AFE filter is a reusable direct replacement for the factory airbox. Jerry Valencia of Diesel Performance Shops simply slid it into place, making sure a seal was made between the element and the air inlet.
The factory airbox lid was...
The factory airbox lid was locked into place. Then we started on the exhaust.
Here, Jerry starts to remove...
Here, Jerry starts to remove the stock exhaust from the back of the diesel particulate filter (DPF). He slid the exhaust over the rear axle (moving forward).
Take a look at the stock exhaust...
Take a look at the stock exhaust tube on left compared to AFE’s larger, 4-inch-diameter tube. The exhaust is mandrel-bent, making it consistent in the bends for unobstructed exhaust flow.
AFE supplies two different...
AFE supplies two different mid-pipes in the kit in order to accommodate different cab configurations and wheelbases.
The exhaust uses the stock...
The exhaust uses the stock frame hanger mount points, adding to the ease of installation and durability.
Here, we are sliding AFE’s...
Here, we are sliding AFE’s one-piece tailpipe over the axle to get it into place.
The exhaust is wiggled and...
The exhaust is wiggled and adjusted, making sure the appropriate tolerance is achieved. Jerry then tightened the frame bracket and hanger clamps.
Moving forward, Jerry maneuvered...
Moving forward, Jerry maneuvered the DPF band clamps into position and tightened them.
With the exhaust system in...
With the exhaust system in place, the exhaust tip was installed while making sure not to cover the vent holes that aid in the cooling during the regeneration process
The polished 304 stainless...
The polished 304 stainless steel exhaust tip was adjusted to give adequate clearance (approximately 1 inch) from body panels. Installation time for the entire exhaust system was about an hour.
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