Fuel injectors

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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 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# ? ? ?
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
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 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 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/37# 462cc/43# ? ? ? 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

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

  • 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 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

Notes