Fuel injectors: Difference between revisions

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==Flow==
==Flow==

{| class="wikitable"
{| class="wikitable"
! colspan="2"|Injector || Rated flow || 2 bar || 3 bar || 3.5 bar || 4 bar || 5 bar || Spray pattern || Length || Connector
! colspan="3"|Injector || Rated flow || 2 bar || 3 bar || 3.5 bar || 4 bar || 5 bar || Cone (α)|| Pattern (β), δ || Bend (γ) || Length || Connector
|-
|-
| Siemens || S4 ||33#@4bar|| || || ||'''349cc/33#'''|| 390cc/37# || || 52mm ||rowspan="9" | EV1
| rowspan="2" | Siemens || rowspan="2" | Deka || S4 || 33#@4bar || || || ||'''349cc/33#'''|| 390cc/37# || rowspan="2"|21° || rowspan="2"|dual 15°, 270° δ || 0° || 52mm ||rowspan="5" | Jetronic
|-
|-
| rowspan="4" | Bosch || Bluetop ||36#@3bar|| 309cc/29# ||'''380cc/36#'''|| || 422cc/40# || 490cc/47# || ||
| RS4 078 133 551 BJ || 46#@4bar || || || ||'''480cc/46#'''|| 538cc/51# || 13°|| 37mm
|-
|-
| RS4 ||46#@4bar|| || || ||'''480cc/46#'''|| 538cc/51# || 15° dual || 1 1/2"
| rowspan="10" | Bosch || colspan="2"|Bluetop ||36#@3bar || 309cc/29# ||'''380cc/36#'''|| || 422cc/40# || 490cc/47# || ? || ? || rowspan=3|0° || ?
|-
|-
| Greentop ||42#@3bar|| ||'''475cc/45#'''|| || 550cc/52# || 615cc/59# || 15° single|| 2 1/2"
| colspan="2"|Greentop ||42#@3bar || ||'''475cc/45#'''|| || 550cc/52# || 615cc/59# || 15° || single || rowspan="2"|64mm
|-
|-
| Green Giant (Volvo)||42#@3bar|| ||'''450cc/43#'''|| || 520cc/50# || 560cc/55# || 15° dual || 2 1/2"
| colspan="2" | Green Giant (Volvo)||42#@3bar|| ||'''450cc/43#'''|| || 520cc/50# || 560cc/55# || 15° || dual
|-
|-
| rowspan="4" colspan="2" | Delphi ||37#@3bar|| ||'''391cc/37#'''|| || 462cc/43# || || ||
| EV6 || 0 280 156 063 ||269g(n-h)@3bar|| ||'''393cc/36#'''|| || 454cc/41# || || 15° || dual 10°, 270° δ || 10° || 52mm || Jetronic
|-
|-
| 38#@3bar|| ||'''399cc/38#'''|| || 462cc/44# || || ||
| rowspan="6" | EV14 || 0 280 158 117||532cc@2.7bar|| ||'''550cc/52#'''|| || 635cc/60# || || rowspan="2"| 15° || rowspan=2|dual 5°, 270° δ|| rowspan=2|12° || rowspan="4"|52mm || rowspan="2"|USCAR
|-
|-
| 42#@3bar|| ||'''441cc/42#'''|| || 515cc/49# || || ||
| 0 280 158 117 (modified) ||750cc@3bar || ||'''750cc/72#'''|| || 865cc/82# ||
|-
|-
| 50##3bar|| ||'''525cc/50#'''|| || 609cc/58# || || 22.4° wide ||
| 0 280 158 123 (997 turbo, GT3RS)||627cc@3bar|| ||'''627cc/60#'''|| || 724cc/69# || 809cc/77# || 25° || dual 7°, 90° δ || 0° || Jetronic
|-
|-
| rowspan="4" | Siemens || Deka IV ('03 SRT4)||41#?@3bar|| ||'''452cc/41#?'''|| || 524cc/47#?|| || Dual? || 52mm ||rowspan="2" | EV6
| 0 280 158 298 (Ford DR3Z-9F593-A)||55#@39.1psi || ||'''627cc/60#'''|| || 724cc/69# || 809cc/77# || 17° || dual 7°, 270° δ || 10° || USCAR
|-
|-
| Deka IV ('04 SRT4)||45#@3bar|| ||'''475cc/45#'''|| || 546cc/52# || || Dual? || 52mm
| 0 280 158 040 ||980cc@3bar || ||'''980cc/93#'''|| || 1031cc/108#|| || 30° || single || 0° || rowspan="2"|37mm || Jetronic
|-
|-
| Deka ID (3172) ||55#@3bar||472cc/45#||'''600cc/57#''' ||624cc/59.5#||667cc/63.5#||746cc/71#|| 15° single|| 2 1/2" ||rowspan="3" | EV1
| B 280 436 469-01 (Motorsport)||1019cc@3bar || ||'''1019cc/97#'''|| || 1176cc/112#|| || 20° || dual 7°, 270° δ || 0°? || Jetronic
|-
|-
| Deka IV (1496) ||60#@3bar ||514cc/49#||'''630cc/60#'''|| || 727cc/70# || || 30.0° wide|| 2 1/2"
| rowspan="4" colspan="3" | Delphi ||37#@3bar || ||'''391cc/35#'''|| || 462cc/43# || || rowspan="3"| ? || rowspan="4"| ? || rowspan="11"| 0° || rowspan="4"| ? || rowspan="4" | Jetronic
|-
|-
| rowspan="3" colspan="2" | Genesis ||415cc@3bar|| ||'''415cc/39#'''|| || 483cc/46# || || Dual || 52mm
| 38#@3bar || ||'''399cc/38#'''|| || 462cc/44# ||
|-
|-
| 430cc@3bar|| ||'''430cc/41#'''|| || 494cc/47# || || Dual || 52mm ||rowspan="2" | EV6
| 42#@3bar || ||'''441cc/42#'''|| || 515cc/49# ||
|-
|-
| 550cc@3bar|| ||'''550cc/52#'''|| 580cc/55# || 635cc/60# || || Dual || 52mm
| 50#@3bar || ||'''525cc/50#'''|| || 609cc/58# || || 22.4°
|-
| rowspan="4" | Siemens || rowspan="4"|Deka || IV ('03 SRT4)||41#?@3bar|| ||'''452cc/41#?'''|| || 524cc/47#?|| || ? || dual? || rowspan="2"|52mm ||rowspan="2" | USCAR
|-
| IV ('04 SRT4)||45#@3bar || ||'''475cc/45#'''|| || 546cc/52# || || ? || dual?
|-
| ID (3172) ||55#@3bar ||472cc/45#||'''600cc/57#'''||624cc/59.5#||667cc/63.5#||746cc/71# || 15° || single|| rowspan="2"|64mm ||rowspan="3" | Jetronic
|-
| IV (1496) ||60#@3bar ||514cc/49#||'''630cc/60#'''|| || 727cc/70# || || 30.0°
|-
| rowspan="3" colspan="3" | Genesis ||415cc@3bar|| ||'''415cc/39#'''|| || 483cc/46# || || ? || rowspan="3"|dual || rowspan="3" | 52mm
|-
| 430cc@3bar|| ||'''430cc/41#'''|| || 494cc/47# || || ? || rowspan="2" | USCAR
|-
| 550cc@3bar|| ||'''550cc/52#'''|| 580cc/55# || 635cc/60# ||
|}
|}


[[Image:EV14_spray_illustration.png|thumb|500px| Bosch spray illustration]]
'''Bold''' denotes the rated pressure.
*'''Bold''' denotes the rated flow/pressure.
*'''Length''' is o-ring center to center.


==Pattern/Orientation==
==Adaptors==
*'''Cone''' angle - Bosch:
**'α80' for single cone (how much angle contains 80% of mass).
**'α50' for dual cone (how much angle contains 50% of mass in both cones)
*'''Pattern''' angle for dual cone - Bosch 'β' (how much angle of one of the cones contains 70% of its individual mass)
*'''Orientation''' angle - Bosch 'δ'
*'''Bend''' angle - Bosch 'γ'

'''Stock injectors are dual cone with 270° δ and have non-zero γ (S4 is 0° γ?)

*Injectors with 90° δ or 270° δ must be clocked with their connectors perpendicular to the block, such that the dual cone is parallel with the block.

*Injectors with 0° δ or 180° δ must be clocked with their connectors parallel to the block, not perpendicular, such that the dual cone is parallel with the block.

*Injectors with non-zero γ must be oriented so their "bend" is oriented into the heads properly.

*Injectors with non-zero γ and a 90° δ cannot be physically clocked correctly, since the physical connector prevents the injector from being clocked such that the bend points in the correct direction.

Note that many 0 280 158 117 injectors modified for greater flow ARE NO LONGER DUAL CONE! Verify before installing.

<br clear=all>

==Spacers==

[[Image:Bosch_EV14_injector_sizes.jpg|thumb|400px| Bosch injector sizing guide]]

2 1/2" (64mm) injectors require 12mm (7/16") rail spacers when using the S4 intake manifold and fuel rail. If you are using an RS4 fuel rail you will need a 1" spacer!
1 1/2" (37mm) injectors require 15mm (9/16") injector spacers with the S4 fuel rail.


{| class="wikitable"
{| class="wikitable"
! mm || inches || Bosch (not c-to-c) || S4 injector spacer || S4 rail spacer || RS4 rail spacer
! || Shape || Bosch || Comment
|-
| 37mm || 1 1/2" || 33.60mm || 15mm (9/16") || N/A || none
|-
|-
| 52mm || 2 1/16" || 48.65mm || none || none || 15mm (9/16")
| EV1 || Rectangle || Design II || Minitimer
|-
|-
| 64mm || 2 1/2" || 60.65mm || N/A || 12mm (7/16") || 27mm (1")
| EV6 || Oval || Design III || USCAR
|}
|}


Note that Bosch's EV14 length specs are not o-ring center to center
Injectors are male, harness is female.


<br style="clear: both"/>
[[Image:USCARR-Bosch-inj-adaptor.jpg|frame|none|USCARR to Bosch fuel injector adaptors]]


==Adaptors==
http://www.fiveomotorsport.com/Injector_CONNECT.asp


[[Image:Jetronic_USCAR_adapter.jpg|thumb|left|100px|[http://www.034motorsport.com/fuel-injection-solutions-injector-connector-adapter-bosch-jetronic-to-uscar-ev14-p-20128.html 034 Motorsport adapter]]]
Note that 2 1/2" injectors require 12mm (7/16") spacers.

{| class="wikitable"
! Connector || Shape || Bosch || A.K.A.
|-
| Jetronic || Rectangle || Design II/EV1 || Minitimer
|-
| USCAR || Oval || Design III/EV6/EV14 ||
|}

Injectors are male, harness is female, so to use a USCAR/EV6/EV14 injector on a Minitimer/Jetronic/EV1 car, you need a USCAR (female) to Jetronic (male) adapter.<ref>http://www.fiveomotorsport.com/electrical-connectors/?itemid=22</ref><ref>http://www.034motorsport.com/fuel-injection-solutions-injector-connector-adapter-bosch-jetronic-to-uscar-ev14-p-20128.html</ref>

<br style="clear: both"/>


==Conversions==
==Conversions==
=== lb/hr to cc/min===
* '''1 lb/hr gasoline = 10.5 cc/min''' (@720 kg/m<sup>3</sup>) - ([http://www.google.com/search?q=%281+lb%2Fhr+%2F+720+kg%2Fm%5E3+%29+in+cc%2Fminute%3D 1 (pound / hr)) / (720 (kg / (m^3)) ])
* '''1 g/min gasoline = 1.39 cc/min''' (@720 kg/m<sup>3</sup>) - ([https://www.google.com/search?q=(1+g%2Fmin+%2F+720+kg%2Fm^3+)+in+cc%2Fminute%3D 1 g/min / 720 kg/m^3 ) in cc/minute=])


=== Flow dependency on pressure ===
* 1 lb/hr gasoline = 10.5 cc/min (@720 kg/m<sup>3</sup>) [http://www.google.com/search?q=%281+lb%2Fhr+%2F+720+kg%2Fm%5E3+%29+in+cc%2Fminute%3D (1 (pound / hr)) / (720 (kg / (m^3))) ]
* <math>Flow_{new}=\sqrt{\frac{P_{new}}{P_{old}}} Flow_{old}</math>
* <math>Flow_{new}=\sqrt{\frac{P_{new}}{P_{old}}} Flow_{old}</math>

* Density of typical test fluid = 760 - 770 kg/m<sup>3</sup>
*: 1 lb/hr = 9.81 - 9.95 cc/min
* Density of n-heptane = 685 kg/m<sup>3</sup>
*: 1 lb/hr = 11.0 cc/min
* 3 bar = 43.5 psi
* 3 bar = 43.5 psi
* 4 bar = 58.0 psi
* 4 bar = 58.0 psi
* 5 bar = 72.5 psi
* 5 bar = 72.5 psi
* RC Engineering's [http://www.rceng.com/technical.htm#WORKSHEET online calculator]
* RC Engineering's [http://www.rceng.com/technical.htm#WORKSHEET online calculator]

* 52mm = 2 1/16"
=== Common test fluids ===
* 2 1/2" = 64mm
* Density of typical test fluid = 760 - 770 kg/m<sup>3</sup>
*: 1 lb/hr = 9.81 - 9.95 cc/min
* Density of n-heptane = 685 kg/m<sup>3</sup>
*: 1 lb/hr = 11.0 cc/min
*: 1 g/min = 1.46 cc/min
*: 1 cc/min = 0.685 g/min


==Instrument cluster==
==Instrument cluster==
If you change fuel injectors, your instrument cluster will estimate your fuel consumption incorrectly. Use [[VAG-COM]] to adjust it by going to Instrument cluster (17) -> Adaptation (10) -> Channel (03).
If you change fuel injectors, your instrument cluster will estimate your fuel consumption incorrectly. Use [[VAG-COM]] to adjust it by going to Instrument cluster (17) -> Adaptation (10) -> Channel (03).<ref>http://forums.audiworld.com/performance/msgs/30668.phtml</ref>


Unfortunately, you can only set it to a maximum of 115%. Default is 100%.
Unfortunately, you can only set it to a maximum of 115%. Default is 100%.


If you have access to ME7.x tuning tools, you can completely fix cluster consumption by adjusting the '''KVB''' 1x1.
If you have access to ME7.x tuning tools, you can completely fix cluster consumption by adjusting the [[Tuning | '''KVB''']] 1x1.


<math>TKVAG = \frac{\sum_{t=0}^{TMAIN} (rk_w+rkte_w) \times KRKTE [ms] \times KVB [cm^3/min] \times 1000}{Kd [mm^3/s] \times 0.0512 [ms] \times 60000}</math>
==References==


==References==
*http://www.bosch-motorsport.de/media/catalog_resources/Injection_Valve_EV_14_Datasheet_51_en_2775993867pdf.pdf - Bosch EV14 data sheet
*http://usrallyteam.com/injectors.html - Genesis
*http://usrallyteam.com/injectors.html - Genesis
*http://racetronix.com/ - Delphi and Siemens
*http://racetronix.com/ - Delphi and Siemens
Line 87: Line 154:
*http://forums.audiworld.com/s4/msgs/2091797.phtml - Flow comparison vs. stock.
*http://forums.audiworld.com/s4/msgs/2091797.phtml - Flow comparison vs. stock.
*http://www.rceng.com/ - RC Engineering
*http://www.rceng.com/ - RC Engineering
*[http://www.usrallyteam.com/content/products/injector/Bosch_Injector_data.xls Bosch injector specifications]
*http://forums.audiworld.com/performance/msgs/30668.phtml - adjusting trip computer estimated fuel consumption for different injector sizes
*http://forums.quattroworld.com/s4/msgs/183984.phtml - Latency and EV14 PDF.

==Notes==
<references/>


[[Category:Tuning]]
[[Category:Tuning]]

Latest revision as of 20:09, 19 July 2021

Flow

Injector Rated flow 2 bar 3 bar 3.5 bar 4 bar 5 bar Cone (α) Pattern (β), δ Bend (γ) Length Connector
Siemens Deka S4 33#@4bar 349cc/33# 390cc/37# 21° dual 15°, 270° δ 0° 52mm Jetronic
RS4 078 133 551 BJ 46#@4bar 480cc/46# 538cc/51# 13° 37mm
Bosch Bluetop 36#@3bar 309cc/29# 380cc/36# 422cc/40# 490cc/47# ? ? 0° ?
Greentop 42#@3bar 475cc/45# 550cc/52# 615cc/59# 15° single 64mm
Green Giant (Volvo) 42#@3bar 450cc/43# 520cc/50# 560cc/55# 15° dual
EV6 0 280 156 063 269g(n-h)@3bar 393cc/36# 454cc/41# 15° dual 10°, 270° δ 10° 52mm Jetronic
EV14 0 280 158 117 532cc@2.7bar 550cc/52# 635cc/60# 15° dual 5°, 270° δ 12° 52mm USCAR
0 280 158 117 (modified) 750cc@3bar 750cc/72# 865cc/82#
0 280 158 123 (997 turbo, GT3RS) 627cc@3bar 627cc/60# 724cc/69# 809cc/77# 25° dual 7°, 90° δ 0° Jetronic
0 280 158 298 (Ford DR3Z-9F593-A) 55#@39.1psi 627cc/60# 724cc/69# 809cc/77# 17° dual 7°, 270° δ 10° USCAR
0 280 158 040 980cc@3bar 980cc/93# 1031cc/108# 30° single 0° 37mm Jetronic
B 280 436 469-01 (Motorsport) 1019cc@3bar 1019cc/97# 1176cc/112# 20° dual 7°, 270° δ 0°? Jetronic
Delphi 37#@3bar 391cc/35# 462cc/43# ? ? 0° ? Jetronic
38#@3bar 399cc/38# 462cc/44#
42#@3bar 441cc/42# 515cc/49#
50#@3bar 525cc/50# 609cc/58# 22.4°
Siemens Deka IV ('03 SRT4) 41#?@3bar 452cc/41#? 524cc/47#? ? dual? 52mm USCAR
IV ('04 SRT4) 45#@3bar 475cc/45# 546cc/52# ? dual?
ID (3172) 55#@3bar 472cc/45# 600cc/57# 624cc/59.5# 667cc/63.5# 746cc/71# 15° single 64mm Jetronic
IV (1496) 60#@3bar 514cc/49# 630cc/60# 727cc/70# 30.0°
Genesis 415cc@3bar 415cc/39# 483cc/46# ? dual 52mm
430cc@3bar 430cc/41# 494cc/47# ? USCAR
550cc@3bar 550cc/52# 580cc/55# 635cc/60#
Bosch spray illustration
  • Bold denotes the rated flow/pressure.
  • Length is o-ring center to center.

Pattern/Orientation

  • Cone angle - Bosch:
    • 'α80' for single cone (how much angle contains 80% of mass).
    • 'α50' for dual cone (how much angle contains 50% of mass in both cones)
  • Pattern angle for dual cone - Bosch 'β' (how much angle of one of the cones contains 70% of its individual mass)
  • Orientation angle - Bosch 'δ'
  • Bend angle - Bosch 'γ'

Stock injectors are dual cone with 270° δ and have non-zero γ (S4 is 0° γ?)

  • Injectors with 90° δ or 270° δ must be clocked with their connectors perpendicular to the block, such that the dual cone is parallel with the block.
  • Injectors with 0° δ or 180° δ must be clocked with their connectors parallel to the block, not perpendicular, such that the dual cone is parallel with the block.
  • Injectors with non-zero γ must be oriented so their "bend" is oriented into the heads properly.
  • Injectors with non-zero γ and a 90° δ cannot be physically clocked correctly, since the physical connector prevents the injector from being clocked such that the bend points in the correct direction.

Note that many 0 280 158 117 injectors modified for greater flow ARE NO LONGER DUAL CONE! Verify before installing.


Spacers

Bosch injector sizing guide

2 1/2" (64mm) injectors require 12mm (7/16") rail spacers when using the S4 intake manifold and fuel rail. If you are using an RS4 fuel rail you will need a 1" spacer! 1 1/2" (37mm) injectors require 15mm (9/16") injector spacers with the S4 fuel rail.

mm inches Bosch (not c-to-c) S4 injector spacer S4 rail spacer RS4 rail spacer
37mm 1 1/2" 33.60mm 15mm (9/16") N/A none
52mm 2 1/16" 48.65mm none none 15mm (9/16")
64mm 2 1/2" 60.65mm N/A 12mm (7/16") 27mm (1")

Note that Bosch's EV14 length specs are not o-ring center to center


Adaptors

034 Motorsport adapter
Connector Shape Bosch A.K.A.
Jetronic Rectangle Design II/EV1 Minitimer
USCAR Oval Design III/EV6/EV14

Injectors are male, harness is female, so to use a USCAR/EV6/EV14 injector on a Minitimer/Jetronic/EV1 car, you need a USCAR (female) to Jetronic (male) adapter.[1][2]


Conversions

lb/hr to cc/min

Flow dependency on pressure

  • 3 bar = 43.5 psi
  • 4 bar = 58.0 psi
  • 5 bar = 72.5 psi
  • RC Engineering's online calculator

Common test fluids

  • Density of typical test fluid = 760 - 770 kg/m3
    1 lb/hr = 9.81 - 9.95 cc/min
  • Density of n-heptane = 685 kg/m3
    1 lb/hr = 11.0 cc/min
    1 g/min = 1.46 cc/min
    1 cc/min = 0.685 g/min

Instrument cluster

If you change fuel injectors, your instrument cluster will estimate your fuel consumption incorrectly. Use VAG-COM to adjust it by going to Instrument cluster (17) -> Adaptation (10) -> Channel (03).[3]

Unfortunately, you can only set it to a maximum of 115%. Default is 100%.

If you have access to ME7.x tuning tools, you can completely fix cluster consumption by adjusting the KVB 1x1.

References

Notes

  1. ↑ http://www.fiveomotorsport.com/electrical-connectors/?itemid=22
  2. ↑ http://www.034motorsport.com/fuel-injection-solutions-injector-connector-adapter-bosch-jetronic-to-uscar-ev14-p-20128.html
  3. ↑ http://forums.audiworld.com/performance/msgs/30668.phtml
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