Returnless Pulse Width Modulation Kit, Ford Gt Fuel Module
Returnless. Manifold referenced. No return line to run. Every OEM builds fuel systems this way now; even the high horsepower ones. A pulse width modulated controller varies pump speed instead of dumping excess fuel back to the tank. This is that system; stand-alone; for a swap. The clever part is the separate manifold pressure sensor. Run a hose from the sensor mount to the intake manifold; set your base pressure; and the controller tracks manifold pressure 1:1 exactly the way a mechanical return-style regulator would. Injectors cannot tell the difference. Neither can your tune. 42 to 60 psi base pressure covers most builds and the controller has range beyond it. Good for up to 25 psi of boost. Pull the vacuum line and it runs constant pressure instead. It drives the pump properly too. 40 amps minimum continuous in a package four inches long; over-temperature shutdown with automatic reset; short circuit protection that survives indefinitely; and at least a 50 percent power reduction to the pump at idle and cruise. All of it in cross-linked polyethylene wire with OEM Delphi connectors. One caution worth reading twice. Do not put an inline filter in front of a modern integrated fuel module.
Install Level: Advanced - fuel system plumbing and controller wiring into the OE ECM
Tailored to the Ford/Motorcraft PFS1215 fuel module using the OEM Delphi/Aptiv connector and terminals. The fuel module is not included.
Do not use an inline fuel filter with a modern integrated fuel module; check valves can trap over 200 psi of key-off heat soak pressure and prevent the engine from starting.
Can be run in constant pressure mode by removing the vacuum line or the MAP sensor wiring.
Lower than 10 volts on the turn on circuit will shut the controller down to protect against a lean condition.
Aeromotive Part Number: 66131
Legacy VaporWorx Part Number: BWGT
The Ford Mustang GT fuel module control system has everything needed to provide a stand alone, manifold referenced, OE-type returnless fuel system.
When used with the low-cost Ford/Motorcraft PFS1215 fuel module the system will provide a 42-60psi base pressure with a 1:1 manifold referenced fuel pressure change for up to 25psi of boost. It will act just like a mechanical fuel pressure regulator would with the ECM tuned in the same manner. The fuel injector does not know if the fuel supplied is pumped by a return or returnless system. Every OEM today, even on the highest horsepower models, use returnless PWM control systems.
The key to making this system simple to use is the stand-alone manifold pressure sensor that tells the controller how to adjust the fuel pressure.
Just like a manifold referenced mechanical fuel pressure regulator, simply connect the hose from the pressure sensor mount to the intake manifold, set the fuel pressure according to the need, and you're done. Base fuel pressures at idle are typically between 42-60psi, but the VaporWorx controller has much greater range if needed.
The controller can also be used with any engine that needs to have a separate MAP sensor for manifold referenced fuel pressure. The kit is tailored to fit the PFS1215 fuel module by using the OEM Delphi/Aptive connector and terminals.
The fuel requirements for all versions of the Ford Controls Pack for the Naturally Aspirated Coyote crate engine can be met with this BoostWorx controller. Can also work up to 25psi forced induction.
NOTE: The Ford Controls Pack for Coyote engines states that a return-type regulator is to be used. This is for two reasons: 1) The fuel pressure must be manifold referenced, and 2) The Ford Controls Pack does not come with a Fuel Pump Driver Module like the modern cars do. The controller does have manifold referenced fuel pressure capability, hence the system will be providing fuel very much the same way as the OEM car. Ford just does not know about VaporWorx since we are the only company to offer a stand-alone electronic returnless fuel system. In other words, no worries!
This kit can also be used in constant pressure mode. Just remove the vacuum line or MAP sensor wiring, and the controller will provide a constant pressure.
Suggested fuel modules:
- Any Gen1-3 naturally aspirated or supercharged Coyote equipped fuel module. Motorcraft PFS1215 suggested. The PFS1215 fuel module can also be used for other applications besides Coyote (Hotrod, LS, SBF, etc.)
- NOTE: It is highly recommended to NOT use an inline fuel filter with a modern integrated fuel module. With the Gen3 GT500 as the exception, a final filter is built into the fuel module. Many aftermarket inline filters have check valves. During key-off engine hot days, heat soak from the engine/exhaust will make the fuel pressure increase, often to over 200psi. Once the key-off pressure goes over about 100psi the injectors can no longer function, hence the car will not start. The check valve does not allow the excessive pressure to bleed off through the safety overpressure valve that is built into the fuel module.
The GT Controller includes these standard features:
- Everything needed electrically to drive the fuel pump module. No relays, external regulators, or return lines needed.
- Unmatched low fuel level capability when combined with the OEM style fuel module.
- A minimum 50% reduction in power to the fuel pump during idle and cruise vs traditional systems.
- 40A minimum continuous power rating in a compact controller package. Total size 4" L x 2.1" W x 1-5/8" H.
- Over-temperature shutdown with automatic reset.
- Short circuit protection that will operate indefinitely without damage.
- OEM Delphi/Aptiv connections for terminals, seals, and connector bodies.
- All cross-linked polyethylene wiring.
- UL94 rated components used throughout.
- Integrates into the OE ECM to allow all safety systems to remain functional.
- 10-22v operating capacity. Can be used with voltage boosters. Lower than 10v applied to the turn on circuit will cause controller shutdown to protect from an AFR lean condition.
Legacy VaporWorx part number BWGT
Base fuel pressure 42-60 psi at idle; greater range available
1:1 manifold referenced fuel pressure change for up to 25 psi of boost
Stand-alone manifold pressure sensor with pressure sensor mount
40A minimum continuous power rating
Controller size 4 inch L x 2.1 inch W x 1-5/8 inch H
Minimum 50 percent reduction in fuel pump power during idle and cruise versus traditional systems
Over-temperature shutdown with automatic reset
Short circuit protection that operates indefinitely without damage
10-22 volt operating capacity; can be used with voltage boosters
OEM Delphi/Aptiv terminals; seals and connector bodies
All cross-linked polyethylene wiring
UL94 rated components used throughout
Integrates into the OE ECM so all safety systems remain functional
Tailored to the Ford/Motorcraft PFS1215 fuel module
Listed price 597.35 USD
Designed around the Ford Mustang GT fuel module and tailored to the Ford/Motorcraft PFS1215 module using OEM Delphi/Aptiv connectors. Any Gen1-3 naturally aspirated or supercharged Coyote fuel module will work.
It also suits any engine that needs a separate MAP sensor for manifold referenced fuel pressure; and it can run in constant pressure mode.
Meets the fuel requirements of all versions of the Ford Controls Pack for the naturally aspirated Coyote crate engine; and works to 25 psi of forced induction.
