Fuel injectors: Difference between revisions

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
Siemens	Deka	RS4 078 133 551 BJ	46#@4bar				480cc/46#	538cc/51#	21°	dual 15°, 270° δ	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		64mm
	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#		15°	dual 5°, 270° δ	12°		USCAR
		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°?	37mm	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?		52mm	USCAR
		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°			64mm
Genesis			415cc@3bar		415cc/39#		483cc/46#		?	dual		52mm
			430cc@3bar		430cc/41#		494cc/47#		?				USCAR
			550cc@3bar		550cc/52#	580cc/55#	635cc/60#						USCAR

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

1 lb/hr gasoline = 10.5 cc/min (@720 kg/m³) - (1 (pound / hr)) / (720 (kg / (m^3)) )
1 g/min gasoline = 1.39 cc/min (@720 kg/m³) - (1 g/min / 720 kg/m^3 ) in cc/minute=)

Flow dependency on pressure

$Flow_{new}={\sqrt {\frac {P_{new}}{P_{old}}}}Flow_{old}$

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.

$TKVAG={\frac {\sum _{t=0}^{TMAIN}(rk_{w}+rkte_{w})\times KRKTE[ms]\times KVB[cm^{3}/min]\times 1000}{Kd[mm^{3}/s]\times 0.0512[ms]\times 60000}}$

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://racetronix.com/ - Delphi and Siemens
http://www.synerject.com/fuelinjectors-dekaIV.html - Custom Siemens Dekas
http://www.fiveomotorsport.com/Injector_SetsMODS.asp - All others
http://www.srtforums.com/forums/showthread.php?t=99710 - SRT4
http://forums.audiworld.com/s4/msgs/2091797.phtml - Flow comparison vs. stock.
http://www.rceng.com/ - RC Engineering
Bosch injector specifications
http://forums.quattroworld.com/s4/msgs/183984.phtml - Latency and EV14 PDF.

Notes

[1] ttp://www.fiveomotorsport.com/electrical-connectors/?itemid=22

[2] ttp://www.034motorsport.com/fuel-injection-solutions-injector-connector-adapter-bosch-jetronic-to-uscar-ev14-p-20128.html

[3] ttp://forums.audiworld.com/performance/msgs/30668.phtml

[1]

[2]

[3]

@@ Line 1: / Line 1: @@
 ==Flow==
 {| 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 (&alpha;)|| Pattern (&beta;), &delta; || Bend (&gamma;) || Length || Connector
 |-
-|             Siemens   || S4       ||33#@4bar||           ||               ||           ||'''349cc/33#'''||390cc/37#||                   || 52mm   ||rowspan="5" | Jetronic
+| rowspan="2" | Siemens || rowspan="2" | Deka || S4 || 33#@4bar || ||       ||       ||'''349cc/33#'''|| 390cc/37# || rowspan="2"|21&deg; || rowspan="2"|dual 15&deg;, 270&deg; &delta; || 0&deg; || 52mm   ||rowspan="5" | Jetronic
 |-
-| rowspan="6" | Bosch   || Bluetop  ||36#@3bar|| 309cc/29# ||'''380cc/36#'''||           || 422cc/40# || 490cc/47# ||                     ||
+|              RS4 078 133 551 BJ || 46#@4bar ||           ||               ||       ||'''480cc/46#'''|| 538cc/51#                               || 13&deg;|| 37mm
 |-
-|                          RS4      ||46#@4bar||           ||               ||           ||'''480cc/46#'''||538cc/51#||15&deg; dual       || 37mm
+| rowspan="10" | Bosch || colspan="2"|Bluetop  ||36#@3bar   || 309cc/29#     ||'''380cc/36#'''|| || 422cc/40# || 490cc/47# || ? || ?         || rowspan=3|0&deg;           || ?
 |-
-|                          Greentop ||42#@3bar||           ||'''475cc/45#'''||           || 550cc/52# || 615cc/59# || 15&deg; single      || rowspan="2"|64mm
+|          colspan="2"|Greentop ||42#@3bar    ||           ||'''475cc/45#'''||           || 550cc/52# || 615cc/59# || 15&deg; || single                    || rowspan="2"|64mm
 |-
-|                Green Giant (Volvo)||42#@3bar||           ||'''450cc/43#'''||           || 520cc/50# || 560cc/55# || 15&deg; dual
+|  colspan="2" | Green Giant (Volvo)||42#@3bar||           ||'''450cc/43#'''||           || 520cc/50# || 560cc/55# || 15&deg; || dual
 |-
-| rowspan="2"|EV14 0280158117 ||rowspan="2"|532cc@2.7bar|| ||   550cc/52#   ||           || 635cc/60# ||           || rowspan="2"|15&deg; dual||rowspan="2"|52mm||rowspan="2"|USCAR
+|              EV6 || 0 280 156 063 ||269g(n-h)@3bar||     ||'''393cc/36#'''||           || 454cc/41# ||           || 15&deg; || dual 10&deg;, 270&deg; &delta; || 10&deg; || 52mm || Jetronic
 |-
-|                                                          || 750cc<ref>034 Motorsport modded?</ref>|| ||          ||
+| rowspan="6" | EV14 || 0 280 158 117||532cc@2.7bar||      ||'''550cc/52#'''||           || 635cc/60# ||           || rowspan="2"| 15&deg; || rowspan=2|dual 5&deg;, 270&deg; &delta;|| rowspan=2|12&deg; || rowspan="4"|52mm || rowspan="2"|USCAR
 |-
-| rowspan="4" colspan="2" | Delphi  ||37#@3bar||           ||'''391cc/37#'''||           || 462cc/43# ||           ||                     ||        ||rowspan="4" | Jetronic
+|      0 280 158 117 (modified)     ||750cc@3bar  ||       ||'''750cc/72#'''||           || 865cc/82# ||
 |-
-|                                     38#@3bar||           ||'''399cc/38#'''||           || 462cc/44# ||           ||                     ||
+|      0 280 158 123 (997 turbo, GT3RS)||627cc@3bar||      ||'''627cc/60#'''||           || 724cc/69# || 809cc/77# || 25&deg; || dual 7&deg;, 90&deg; &delta;  || 0&deg;       || Jetronic
 |-
-|                                     42#@3bar||           ||'''441cc/42#'''||           || 515cc/49# ||           ||                     ||
+|  0 280 158 298 (Ford DR3Z-9F593-A)||55#@39.1psi ||       ||'''627cc/60#'''||           || 724cc/69# || 809cc/77# || 17&deg; || dual 7&deg;, 270&deg; &delta; || 10&deg;    || USCAR
 |-
-|                                     50#@3bar||           ||'''525cc/50#'''||           || 609cc/58# ||           || 22.4&deg; wide      ||
+|      0 280 158 040                ||980cc@3bar  ||       ||'''980cc/93#'''||           || 1031cc/108#||          || 30&deg; || single ||  0&deg;   || rowspan="2"|37mm || Jetronic
 |-
-| rowspan="4" | Siemens || Deka IV ('03 SRT4)||41#?@3bar|| ||'''452cc/41#?'''||          || 524cc/47#?||           || Dual?               || rowspan="2"|52mm   ||rowspan="2" | USCAR
+|      B 280 436 469-01 (Motorsport)||1019cc@3bar ||       ||'''1019cc/97#'''||          || 1176cc/112#||          || 20&deg; || dual 7&deg;, 270&deg; &delta; || 0&deg;? || Jetronic
 |-
-|                          Deka IV ('04 SRT4)||45#@3bar||  ||'''475cc/45#'''||           || 546cc/52# ||           || Dual?
+| rowspan="4" colspan="3" | Delphi  ||37#@3bar    ||       ||'''391cc/35#'''||           || 462cc/43# ||           || rowspan="3"| ?   || rowspan="4"| ? || rowspan="11"| 0&deg; || rowspan="4"| ? || rowspan="4" | Jetronic
 |-
-|                          Deka ID (3172)    ||55#@3bar||472cc/45#||'''600cc/57#''' ||624cc/59.5#||667cc/63.5#||746cc/71#|| 15&deg; single|| rowspan="2"|2 1/2" ||rowspan="3" | Jetronic
+|                                     38#@3bar    ||       ||'''399cc/38#'''||           || 462cc/44# ||
 |-
-|                          Deka IV (1496)    ||60#@3bar ||514cc/49#||'''630cc/60#'''||         || 727cc/70# ||     || 30.0&deg; wide
+|                                     42#@3bar    ||       ||'''441cc/42#'''||           || 515cc/49# ||
 |-
-| rowspan="3" colspan="2" | Genesis ||415cc@3bar||           ||'''415cc/39#'''||           || 483cc/46# ||         || Dual                || rowspan="3" | 52mm
+|                                     50#@3bar    ||       ||'''525cc/50#'''||           || 609cc/58# ||           || 22.4&deg;
 |-
-|                                     430cc@3bar||           ||'''430cc/41#'''||           || 494cc/47# ||         || Dual                || rowspan="2" | USCAR
+| rowspan="4" | Siemens || rowspan="4"|Deka || IV ('03 SRT4)||41#?@3bar|| ||'''452cc/41#?'''|| || 524cc/47#?||     || ?       || dual?               || rowspan="2"|52mm   ||rowspan="2" | USCAR
 |-
-|                                     550cc@3bar||           ||'''550cc/52#'''|| 580cc/55# || 635cc/60# ||         || Dual
+|                      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&deg;  || single|| rowspan="2"|64mm   ||rowspan="3" | Jetronic
+|-
+|                      IV (1496)    ||60#@3bar  ||514cc/49#||'''630cc/60#'''||           || 727cc/70# ||           || 30.0&deg;
+|-
+| 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:
+**'&alpha;80' for single cone (how much angle contains 80% of mass).
+**'&alpha;50' for dual cone (how much angle contains 50% of mass in both cones)
+*'''Pattern''' angle for dual cone - Bosch '&beta;' (how much angle of one of the cones contains 70% of its individual mass)
+*'''Orientation''' angle - Bosch '&delta;'
+*'''Bend''' angle - Bosch '&gamma;'
+'''Stock injectors are dual cone with 270&deg; &delta; and have non-zero &gamma; (S4 is 0&deg; &gamma;?)
+*Injectors with 90&deg; &delta; or 270&deg; &delta; must be clocked with their connectors perpendicular to the block, such that the dual cone is parallel with the block.
+*Injectors with 0&deg; &delta; or 180&deg; &delta; 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 &gamma; must be oriented so their "bend" is oriented into the heads properly.
+*Injectors with non-zero &gamma; and a 90&deg; &delta; 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]]
+[[Image:Bosch_EV14_injector_sizes.jpg|thumb|400px| Bosch injector sizing guide]]
-1/2" (64mm) 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!
+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!
+1/2" (37mm) injectors require 15mm (9/16") injector spacers with the S4 fuel rail.
 {| class="wikitable"
-! mm || inches || Bosch (not c-to-c) || S4 rail spacer || RS4 rail spacer
+! mm || inches || Bosch (not c-to-c) || S4 injector spacer || S4 rail spacer || RS4 rail spacer
 |-
-| 37mm || 1 1/2"  || 33.60mm         || N/A            || none
+| 37mm || 1 1/2"  || 33.60mm         || 15mm (9/16")       || N/A            || none
 |-
-| 52mm || 2 1/16" || 48.65mm         || none           || 15mm (9/16")
+| 52mm || 2 1/16" || 48.65mm         || none               || none           || 15mm (9/16")
 |-
-| 64mm || 2 1/2"  || 60.65mm         || 12mm (7/16")   || 27mm (1")
+| 64mm || 2 1/2"  || 60.65mm         || N/A                || 12mm (7/16")   || 27mm (1")
 |}
@@ Line 71: / Line 106: @@
 ! Connector || Shape || Bosch || A.K.A.
 |-
-| Jetronic || Rectangle || Design II || EV1/Minitimer
+| Jetronic || Rectangle || Design II/EV1 || Minitimer
 |-
-| USCAR || Oval || Design III || EV6/EV14
+| USCAR || Oval || Design III/EV6/EV14 ||
 |}
@@ Line 81: / Line 116: @@
 ==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>
-* 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
 * 4 bar = 58.0 psi
 * 5 bar = 72.5 psi
 * RC Engineering's [http://www.rceng.com/technical.htm#WORKSHEET online calculator]
+=== Common test fluids ===
+* 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==
@@ Line 99: / Line 142: @@
 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==
+*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://racetronix.com/ - Delphi and Siemens
@@ Line 109: / Line 155: @@
 *http://www.rceng.com/ - RC Engineering
 *[http://www.usrallyteam.com/content/products/injector/Bosch_Injector_data.xls Bosch injector specifications]
+*http://forums.quattroworld.com/s4/msgs/183984.phtml - Latency and EV14 PDF.
 ==Notes==

Fuel injectors: Difference between revisions

Latest revision as of 20:09, 19 July 2021

Contents

Flow

Pattern/Orientation

Spacers

Adaptors

Conversions

lb/hr to cc/min

Flow dependency on pressure

Common test fluids

Instrument cluster

References

Notes

Navigation menu

Fuel injectors: Difference between revisions

Latest revision as of 20:09, 19 July 2021

Flow

Pattern/Orientation

Spacers

Adaptors

Conversions

lb/hr to cc/min

Flow dependency on pressure

Common test fluids

Instrument cluster

References

Notes

Navigation menu

Search