Here it is, Everything you need to run a 4 lobe fuel pump set up.
[edit]. Also Everything you need to run RS injectors.
Continuing off a previous discussion:
www.focusst.org
I started a new thread with everything included as a reference guide for anyone interested.
Why would you want to do this? the 2.3L 4 lobe fuel pump flows about 25% more fuel per rev and can dish out 700 psi more than the 2.0L 3 lobe fuel pump.
Additionally, this opens up our platform to all 2.3L camshaft sets. (particularly, the affordably priced Ford Racing Performance Mustang camshafts)
This offers an improvement in fueling and camshaft upgrade for a fraction of the cost of staged 3 lobe camshafts.
If you find a used RS fuel pump it can be done for about $425 (neglecting welder labor cost, but including material)
Parts you will need:
![392200]()
As far as cams, any 4 lobe cam for the RS, Flexfuel Ti-VCT, or mustang will work, so long as you do your build right (i.e. upgraded valve springs if needed)
If you do not want to mess with new springs or valves, there are three options:
[edit 6/28/21] - The Ti-VCT flex fuel also features a 4 lobe fuel pump cam for driving the higher flowing E85 HPFP. I would assume the cam profile to be similar to the 2.0L EB in terms of lift, however it could be different in regard to duration since the Ti-VCT is naturally aspirated. Not sure.
Fabrication:
Unfortunately there is a little itty bit of fabrication involved for this modification. Its perfectly doable. I'm not a welder and I did fine with the right tools and some practice. Three of the four fuel pump cover mounting bolts line up. the other one does not. This lends itself to a bit of aluminum weld work.
[edit] @Moment is trying out a Plug and Play option using a 2.3L camshaft cap directly. This option may be more feasible. See discussion after post #32 of this thread
www.focusst.org
[edit] - "itty bit" is humor. Practice practice practice or pay for a welder to help.
![392206]()
You can see the additional Tapped Hole that I have added. I made this piece so that I could still reuse the old Fuel pump for a 3 lobe cam if I ever wanted to go back. The old oiling port in red needs to be plugged and ground flush.
The hole highlighted in blue is the new oiling port. Ford left this port here and blocked it off with the 3 lobe cam cover. It seems they anticipated needing a different oiling route in the future. They cashed in on their foresight with the 4 lobe cam cover (it uses this route) Thanks Ford!
![392215]()
To locate the new tapped hole correctly, you must have the new fuel cover assembled (with 3 bolts) to scribe a hole. The bolt circled in red here is almost good, but not. You have to file out the hole in the RS cover a little bit to make it fit.
![392208]()
Sketched up instructions.
![392203]()
I wasn't as careful with the back because I had full penetration very solid welds on the front mating face, and I didn't want to put any more heat into the part than I needed. Note that I had to grind out the entry for the cam cap bolt.
Important: The camshaft bearing face is a precision tolerance face. Take great care to leave it intact.
If you alter the bearing face, you will likely need to replace the entire cylinder head. This part is line bored with the other cam caps and is not sold individually. It is unique to your engine. This is also why you can't just go out and buy the RS one. As far as weld warping goes, I went nuts on this thing and poured tons of heat into it. There was no detectable warpage in camshaft bearing bore to less than a measurable thousandth (<0.001) This is due to the lovely nature of small aluminum parts heating evenly. The whole thing heats up and cools down at a uniform temperature which makes this all possible.
Welder settings:
2022 update: @Moment pulled a Cam Cap from a 2.3L engine fand skipped all of the TIG welding fun. It is a seemingly Plug and Play option. Post #32 of this thread:
www.focusst.org
If you have no weld experience and you want to do this mod. First off I'd say, I had zero TIG welding experience and for a bout a week during my lunch break I would go and practice TIG welding on some spare aluminum plate. On the last friday that week I bit the bullet and did it. With about 5 hours of practice I got it done. Secondly I'd say there are plenty of aluminum welders out there that repair crankcases all the time. This would be right in their wheel house. Make the weld on stub and take it to them.
ECU calibration
The stock ST ECU never saw this comin. But with the correct paramters, the 4 lobe fuel pump fits into the ECU strategy quite comfortaby. Most of the parameters I copy straight from the RS, while a few I found worked better to leave the ST values in (things pertaining to the fuel rail). The MFV latency tables (Mass fuel valve) are a bit less complex on the ST ECU so I interpolated values and ended up with a result that works well. Ultimately these MFV tables must be simliar to the RS's for smooth operation. The one table that is subject to preference is Fuel Pressure desired. This table is up to you and/or your tuner. However the table I have made is nice mix between the ST and RS. The car likes it well. The Stock ST injectors never flow enough fuel to call for 2900 psi with my tiny turbo setup, but it has table values ready if they ever decide to.
If you copy the blue values in from my spreadsheet you will be in for a very smooth 4 lobe fuel pump conversion.
I have spent ~30 hr. tuning these parameters and I'm confident in this configuration.
![392218]()
![392213]()
![392214]()
Though the welding was a bit of a curveball, Its perfectly doable. Any aluminum welder should be able to do it. Anyone who does crankcase repair would make quick work of it.
All in all its pretty slick. If you have the Camshafts out for any reason I'd seriously consider doing this mod.
The whole reason I went down this rabbit hole was because I was doing a cylinder head gasket job and saw that Ford has high performance camshafts on sale for $180. The end result is a fuel system that is much more capable.
[edit]. Also Everything you need to run RS injectors.
Continuing off a previous discussion:
Camshaft upgrade (2.3L mustang cams on 2.0L)
It looks like I’m going to be doing a head gasket replacement soon. I may upgrade the cams while I’m in there. Not interested in mountune’s overpriced cams (also had an unpleasant experience with their sales guy) but the only other option that I’ve seen so far are piper cam’s options. Anyone...
www.focusst.org
Why would you want to do this? the 2.3L 4 lobe fuel pump flows about 25% more fuel per rev and can dish out 700 psi more than the 2.0L 3 lobe fuel pump.
Additionally, this opens up our platform to all 2.3L camshaft sets. (particularly, the affordably priced Ford Racing Performance Mustang camshafts)
This offers an improvement in fueling and camshaft upgrade for a fraction of the cost of staged 3 lobe camshafts.
If you find a used RS fuel pump it can be done for about $425 (neglecting welder labor cost, but including material)
Parts you will need:
- RS fuel pump - EJ7Z-9350-A Actively Investigating the plausibly of 2.0L Ti-VCT Flex Fuel pump compatibility.
- RS fuel pump cam cover - https://parts.ford.com/shop/en/us/cover-fuel-pump-6412113-1#sectionId:141071901
- RS fuel pump roller tappet -
- RS high pressure fuel line - (part number needed) ( I just bent my ST line on a bench vice until it lined up)
- A bit of 1/2 inch 6061 aluminum plate -
McMaster-Carr
McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.
www.mcmaster.com
- ER 4043 3/32" Aluminum tig Filler rod -
McMaster-Carr
McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.
www.mcmaster.com
As far as cams, any 4 lobe cam for the RS, Flexfuel Ti-VCT, or mustang will work, so long as you do your build right (i.e. upgraded valve springs if needed)
If you do not want to mess with new springs or valves, there are three options:
- Ford Racing Performance 2.3L ecoboost High performance Cams -
2015-2021 2.3L ECOBOOST HIGH PERFORMANCE CAMS
2015-2021 2.3L ECOBOOST HIGH PERFORMANCE CAMS|Ford Performance Parts
performanceparts.ford.com
- Stock focus RS or EB mustang camshafts - BB5Z-6250-B and EJ7Z-6250-A
- 2.0L Ti-VCT FlexFuel cams - CM5Z-6250-K and CM5Z-6250-L
[edit 6/28/21] - The Ti-VCT flex fuel also features a 4 lobe fuel pump cam for driving the higher flowing E85 HPFP. I would assume the cam profile to be similar to the 2.0L EB in terms of lift, however it could be different in regard to duration since the Ti-VCT is naturally aspirated. Not sure.
Fabrication:
Unfortunately there is a little itty bit of fabrication involved for this modification. Its perfectly doable. I'm not a welder and I did fine with the right tools and some practice. Three of the four fuel pump cover mounting bolts line up. the other one does not. This lends itself to a bit of aluminum weld work.
[edit] @Moment is trying out a Plug and Play option using a 2.3L camshaft cap directly. This option may be more feasible. See discussion after post #32 of this thread
4 lobe fuel pump ( ft. RS injectors ): All-in-one...
If you were big turbo, you'd still need a better fuel solution eventually. This mod would buy you some more Hp before you ran into that point, but RS's still run out of fuel like an ST.. Just a few ponies later in the quest for power.
www.focusst.org
[edit] - "itty bit" is humor. Practice practice practice or pay for a welder to help.
You can see the additional Tapped Hole that I have added. I made this piece so that I could still reuse the old Fuel pump for a 3 lobe cam if I ever wanted to go back. The old oiling port in red needs to be plugged and ground flush.
The hole highlighted in blue is the new oiling port. Ford left this port here and blocked it off with the 3 lobe cam cover. It seems they anticipated needing a different oiling route in the future. They cashed in on their foresight with the 4 lobe cam cover (it uses this route) Thanks Ford!
To locate the new tapped hole correctly, you must have the new fuel cover assembled (with 3 bolts) to scribe a hole. The bolt circled in red here is almost good, but not. You have to file out the hole in the RS cover a little bit to make it fit.
Sketched up instructions.
I wasn't as careful with the back because I had full penetration very solid welds on the front mating face, and I didn't want to put any more heat into the part than I needed. Note that I had to grind out the entry for the cam cap bolt.
Important: The camshaft bearing face is a precision tolerance face. Take great care to leave it intact.
If you alter the bearing face, you will likely need to replace the entire cylinder head. This part is line bored with the other cam caps and is not sold individually. It is unique to your engine. This is also why you can't just go out and buy the RS one. As far as weld warping goes, I went nuts on this thing and poured tons of heat into it. There was no detectable warpage in camshaft bearing bore to less than a measurable thousandth (<0.001) This is due to the lovely nature of small aluminum parts heating evenly. The whole thing heats up and cools down at a uniform temperature which makes this all possible.
Welder settings:
- Multimix tungsten electrode, mild pointed tip, straight cullet
- AC welding, 120Hz preffered but if your welder cant do that don't worry.
- 65% inflow, 35% cleaning flow out of the part.
- pulsing 3 times a second
- 150 amps
- 15 psi of shielding gas (used Argon)
2022 update: @Moment pulled a Cam Cap from a 2.3L engine fand skipped all of the TIG welding fun. It is a seemingly Plug and Play option. Post #32 of this thread:
4 lobe fuel pump ( ft. RS injectors ): All-in-one...
If you were big turbo, you'd still need a better fuel solution eventually. This mod would buy you some more Hp before you ran into that point, but RS's still run out of fuel like an ST.. Just a few ponies later in the quest for power.
www.focusst.org
If you have no weld experience and you want to do this mod. First off I'd say, I had zero TIG welding experience and for a bout a week during my lunch break I would go and practice TIG welding on some spare aluminum plate. On the last friday that week I bit the bullet and did it. With about 5 hours of practice I got it done. Secondly I'd say there are plenty of aluminum welders out there that repair crankcases all the time. This would be right in their wheel house. Make the weld on stub and take it to them.
ECU calibration
The stock ST ECU never saw this comin. But with the correct paramters, the 4 lobe fuel pump fits into the ECU strategy quite comfortaby. Most of the parameters I copy straight from the RS, while a few I found worked better to leave the ST values in (things pertaining to the fuel rail). The MFV latency tables (Mass fuel valve) are a bit less complex on the ST ECU so I interpolated values and ended up with a result that works well. Ultimately these MFV tables must be simliar to the RS's for smooth operation. The one table that is subject to preference is Fuel Pressure desired. This table is up to you and/or your tuner. However the table I have made is nice mix between the ST and RS. The car likes it well. The Stock ST injectors never flow enough fuel to call for 2900 psi with my tiny turbo setup, but it has table values ready if they ever decide to.
If you copy the blue values in from my spreadsheet you will be in for a very smooth 4 lobe fuel pump conversion.
I have spent ~30 hr. tuning these parameters and I'm confident in this configuration.
Though the welding was a bit of a curveball, Its perfectly doable. Any aluminum welder should be able to do it. Anyone who does crankcase repair would make quick work of it.
All in all its pretty slick. If you have the Camshafts out for any reason I'd seriously consider doing this mod.
The whole reason I went down this rabbit hole was because I was doing a cylinder head gasket job and saw that Ford has high performance camshafts on sale for $180. The end result is a fuel system that is much more capable.
