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" | Jetronic
| 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" | USCAR
| 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" | Jetronic
| 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" | USCAR
| 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==
*'''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==
==Spacers==


[[Image:Bosch_EV14_injector_sizes.jpg|thumb|400px| Bosch injector sizing guide]]
2 1/2" injectors require 12mm (7/16") spacers when using the S4 intake manifold and fuel rail. If you are using an RS4 fuel rail you will need a 1" spacer!


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!
==Adaptors==
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")
| Jetronic || Rectangle || Design II || EV1/Minitimer
|-
|-
| 64mm || 2 1/2" || 60.65mm || N/A || 12mm (7/16") || 27mm (1")
| USCAR || Oval || Design III || EV6/EV14
|}
|}


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]]]

{| 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%.
Line 81: Line 143:
If you have access to ME7.x tuning tools, you can completely fix cluster consumption by adjusting the [[Tuning | '''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 90: 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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