Fuel injectors

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.

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).

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.