n xntrx volvo
10-02-2004, 09:11 PM
just saving this till i can work on it tommorrow in case my computer crashes.
please no comments till i finish
Fuel System Upgrades
for help w/ abbreviations go here (http://forums.turbobricks.com/showthread.php?t=23670)
Injectors
http://wwwrsphysse.anu.edu.au/%7Eamh110/all_gifs/Turbo%20page%20gifs/injector_explode.jpg
Stock injectors
357= the bosch 357 injectors that came stock in the 84-89 b230ft motor 29lb/hr (300cc/min) @ 3bar
804= the bosch 804 injectors that came stock in the 90+ b230ft rated 30lb/hr(310cc/min) @ 3 bar
Upgrades
Info by part number for injectors (http://users.erols.com/srweiss/tableifc.htm)
Info for import injectors (http://www.robietherobot.com/storm/fuelinjectorguide.htm)
Info for ford injectors (http://www.turboford.org/faq/injectors.shtml)
cfi's
-v6
found in ford v6 cfi carspart# 0 280 150 402.
38.8lb/hr(407cc/min) @ 3 bar,
43.4lb/hr (456cc/min) @4 bar.
-These injectors are more common and easier to find. Though the only down side is they are CFI design so they can't not use the OEM injector clips. Though this fit and work in our setups perfect. They are as big as the brown tops but because of the CFI design the injector spray is a little finer of a mist and a wider spray pattern.
http://www.turboford.org/faq/images/cfi-inj.jpg
-To make these fit in a volvo manifold all you need is 2 orings on the bottom and 1 spacer and one oring on the top. w/ this setup i have NEVER had a CFI injector leak from not sealing over time... only leak beacuse i didn't make sure the oring sat/sealed right.
-The lower right injector shows what needs to be done to make fit in a volvo rail/manifold.
first you remove the plastic stock CFI cap and then clean the body of the injector(or u can leave it be) and then u just put the two orings on the bottom and then one spacer and oring on the top.
http://www.ifiruledtheworld.com/%7Epriest/Host/sIMG_5833.jpg
-v8
ford/bosch injector found on 80-85 ford 5.0 CFI motors(look like TBI).
part # 280 150 403
59lb/hr 620cc/min (3bar)
these injectors are good until about 430 hp
browntops
87-88 ford turbo coupes(t-birds) and mercury cougar xr7, 84-86 mustang svo, 87-89 merkur xr4ti's.
Ford part # on the side is E5ZE
38lb/hr. 400cc/min (3 bar)
42lb/hr 450cc/min (4 bar)
lh 2.2 install (http://forums.turbobricks.com/showthread.php?t=20676)
starian/ conquest
the mitsu starion/conquest motors have 80lb/hr injectors
http://www.ifiruledtheworld.com/%7Epriest/Host/starion.jpg
800cc primary and like a 1200 cc secondary
these are un-tested
Install notes for upgraded injectors
lh 2.4, adjusts itself
lh 2.2, resistor mods needed to amm, see lh install (http://forums.turbobricks.com/showthread.php?t=20676) in browntops
Non-turbo models, 4 x 10ohm resistors are required in line from the ecu.
Cleaning
Cruzin Performance (http://www.cruzinperformance.com/fuelinj.html)
$11 per injector to be cleaned and flowed
RC Engineering, CA (http://www.rceng.com/)
$25 per injector to be cleaned and flowed. prob the best shop with the fastest turn around.
home ultrasonic cleaning (http://www.brickboard.com/FAQ/700-900/EngineFuelinjection.htm#Homemade_Fuel_Injector_Cle aner)
Accurate Technical Services in MI (http://www.CleanInjectors.com)
$11 per injector to be cleaned and flowed.
Marren Motorsports in CT
$25 per injector to be cleaned and flowed.
FPR
stock (lh)
n/a 2.5 bar
turbo 3 bar
Dodge 4bar
4 bar FPR found any of the mid/late 80's turbo dodges w/ the newer style intake manifold (that draw throw but blow through like ours). there is the one style that look just like the OEM one jsut w/ the 1/4 barb on the backand then there is the later model one which has a thread in fitting for the return line. Both injectors for each car are rated/sold as lb/hb @ 55psi(4 baR). bosch part # 280 160 260. mopar # 4306015 437. these bolt right into the volvo rail and will need a 1/4 fuel line to go from the return line on the FPR to the tank. this is a little smaller than the stock return line. this is a 4 bar FPR ... takes fuel pressure up to 55psi.
Fuel Pumps
-K-jet
K jet pumps together flow 120-140 L/h @ 5bar
-lh turbo
LH jet pumps together flow 120 L/h @ 3bar
-Walbro
255lph hp
part # gss342 hp
also sold under holley brand
#'s 12-913, 12-915, 12-916, 12-918, 12-919, 12-921, and 12-922.
these just replace the in tank unit, you bypass the front one
these will fit in the stock pre-pumo (in tank) location. use the supplied walbro pre pump filter (sock).
-mods to fit
-minor grinding on the inside of the holder. the ridges plus a bit.
-the pipe that exts the tank that it connects to gets shortened 1"
-it needs to be wired in through a relay to prevent burning up the wires. just use the stock in-tank and fuel sender power wire as the swiched power source. add a couple fuses.
Specs at 13.5v
psi, amps, gal/hr, ltr/hr, ..cc/min. ..bhp
35 ..7.5 ....76.5 ..289.59 4826.51 ..765
45 ..8.2 ....74 ....273.82 .4568.63 ..723.3
55 ..9 68...17 .....258.04 4300.75 ...681.7
65 ..10.2 ..62.33 .244.16 4069.41 ...645
75 ..10.7 ..60.5 ...229.02 3817.05 ..605
85 ..11.6 ..50.17 .189.91 3165.1 ....501.7
(bsfc est @ .70)
at 16.5v
45 ..11.6 ..91.5 ..346.37 .5772.89 ..915
65 ..14.1 ..80 .....302.84 .5047.33 ..800
85 ..16.2 ..62.33 .235.96 .3932.71 ..623.3
the bypass opens at 85 psi.
MSD in-line
part # 2225
pros
goes in an easier to get to position
cons,
no bypass valve
cost
can only supply as mush fuel as the in-tank can provide
Voltage booster
By increasing the voltage to the pumps, you can also increase the flow. Can be used when changing pump is not desirible or when performance pump capacity has been reached.
Availible from
MSD (http://www.msdignition.com/tc_24.htm)
Dual Pumps
By doubling the pumps, you double the flow. Works best on large in-tank pumps. does require fabrication. dont forget to double up on the wiring too!
Fuel Rail
You can buy fuel rail blanks at www.atpturbo.com (http://www.atpturbo.com)
Equations
Maximum Horsepower with a Given Injector Size
(Flow Rate * No. of Injectors * 0.8) / (BSFC) = HP
Convert cfm to Estimated Injector Size
(CFM * 0.44298) / No. of Cylinders = Estimated Injector Size
Optimum Injector Size Equation:
(BHP * BSFC) / (No. of Injectors * 0.8) = Injector Size (Flow Rate)
Conversions: 1 atmosphere = 14.7 psi, 1 atmosphere = 101.3 kPa ,1 atmosphere = 1.013 BAR, 1 BAR = 14.51 psi Volume Conversions: [lbs/hour = Cubic centimetres (cc) per minute / 10.2] ; [cc per minute = lbs/hour x 10.2]
cc per minute = HP x 5 , HP (per injector) = cc per minute / 5 , HP = lbs per hour x 2.04
other reading
anthony hyde (http://wwwrsphysse.anu.edu.au/%7Eamh110/Technical_pages/bosch_403_fuel_injector.htm)
work in progress, part of a larger easy to find topics , will add info as needed
thanks to mike (thestartof) where most of this info came from, along w/ everyone else
please no comments till i finish
Fuel System Upgrades
for help w/ abbreviations go here (http://forums.turbobricks.com/showthread.php?t=23670)
Injectors
http://wwwrsphysse.anu.edu.au/%7Eamh110/all_gifs/Turbo%20page%20gifs/injector_explode.jpg
Stock injectors
357= the bosch 357 injectors that came stock in the 84-89 b230ft motor 29lb/hr (300cc/min) @ 3bar
804= the bosch 804 injectors that came stock in the 90+ b230ft rated 30lb/hr(310cc/min) @ 3 bar
Upgrades
Info by part number for injectors (http://users.erols.com/srweiss/tableifc.htm)
Info for import injectors (http://www.robietherobot.com/storm/fuelinjectorguide.htm)
Info for ford injectors (http://www.turboford.org/faq/injectors.shtml)
cfi's
-v6
found in ford v6 cfi carspart# 0 280 150 402.
38.8lb/hr(407cc/min) @ 3 bar,
43.4lb/hr (456cc/min) @4 bar.
-These injectors are more common and easier to find. Though the only down side is they are CFI design so they can't not use the OEM injector clips. Though this fit and work in our setups perfect. They are as big as the brown tops but because of the CFI design the injector spray is a little finer of a mist and a wider spray pattern.
http://www.turboford.org/faq/images/cfi-inj.jpg
-To make these fit in a volvo manifold all you need is 2 orings on the bottom and 1 spacer and one oring on the top. w/ this setup i have NEVER had a CFI injector leak from not sealing over time... only leak beacuse i didn't make sure the oring sat/sealed right.
-The lower right injector shows what needs to be done to make fit in a volvo rail/manifold.
first you remove the plastic stock CFI cap and then clean the body of the injector(or u can leave it be) and then u just put the two orings on the bottom and then one spacer and oring on the top.
http://www.ifiruledtheworld.com/%7Epriest/Host/sIMG_5833.jpg
-v8
ford/bosch injector found on 80-85 ford 5.0 CFI motors(look like TBI).
part # 280 150 403
59lb/hr 620cc/min (3bar)
these injectors are good until about 430 hp
browntops
87-88 ford turbo coupes(t-birds) and mercury cougar xr7, 84-86 mustang svo, 87-89 merkur xr4ti's.
Ford part # on the side is E5ZE
38lb/hr. 400cc/min (3 bar)
42lb/hr 450cc/min (4 bar)
lh 2.2 install (http://forums.turbobricks.com/showthread.php?t=20676)
starian/ conquest
the mitsu starion/conquest motors have 80lb/hr injectors
http://www.ifiruledtheworld.com/%7Epriest/Host/starion.jpg
800cc primary and like a 1200 cc secondary
these are un-tested
Install notes for upgraded injectors
lh 2.4, adjusts itself
lh 2.2, resistor mods needed to amm, see lh install (http://forums.turbobricks.com/showthread.php?t=20676) in browntops
Non-turbo models, 4 x 10ohm resistors are required in line from the ecu.
Cleaning
Cruzin Performance (http://www.cruzinperformance.com/fuelinj.html)
$11 per injector to be cleaned and flowed
RC Engineering, CA (http://www.rceng.com/)
$25 per injector to be cleaned and flowed. prob the best shop with the fastest turn around.
home ultrasonic cleaning (http://www.brickboard.com/FAQ/700-900/EngineFuelinjection.htm#Homemade_Fuel_Injector_Cle aner)
Accurate Technical Services in MI (http://www.CleanInjectors.com)
$11 per injector to be cleaned and flowed.
Marren Motorsports in CT
$25 per injector to be cleaned and flowed.
FPR
stock (lh)
n/a 2.5 bar
turbo 3 bar
Dodge 4bar
4 bar FPR found any of the mid/late 80's turbo dodges w/ the newer style intake manifold (that draw throw but blow through like ours). there is the one style that look just like the OEM one jsut w/ the 1/4 barb on the backand then there is the later model one which has a thread in fitting for the return line. Both injectors for each car are rated/sold as lb/hb @ 55psi(4 baR). bosch part # 280 160 260. mopar # 4306015 437. these bolt right into the volvo rail and will need a 1/4 fuel line to go from the return line on the FPR to the tank. this is a little smaller than the stock return line. this is a 4 bar FPR ... takes fuel pressure up to 55psi.
Fuel Pumps
-K-jet
K jet pumps together flow 120-140 L/h @ 5bar
-lh turbo
LH jet pumps together flow 120 L/h @ 3bar
-Walbro
255lph hp
part # gss342 hp
also sold under holley brand
#'s 12-913, 12-915, 12-916, 12-918, 12-919, 12-921, and 12-922.
these just replace the in tank unit, you bypass the front one
these will fit in the stock pre-pumo (in tank) location. use the supplied walbro pre pump filter (sock).
-mods to fit
-minor grinding on the inside of the holder. the ridges plus a bit.
-the pipe that exts the tank that it connects to gets shortened 1"
-it needs to be wired in through a relay to prevent burning up the wires. just use the stock in-tank and fuel sender power wire as the swiched power source. add a couple fuses.
Specs at 13.5v
psi, amps, gal/hr, ltr/hr, ..cc/min. ..bhp
35 ..7.5 ....76.5 ..289.59 4826.51 ..765
45 ..8.2 ....74 ....273.82 .4568.63 ..723.3
55 ..9 68...17 .....258.04 4300.75 ...681.7
65 ..10.2 ..62.33 .244.16 4069.41 ...645
75 ..10.7 ..60.5 ...229.02 3817.05 ..605
85 ..11.6 ..50.17 .189.91 3165.1 ....501.7
(bsfc est @ .70)
at 16.5v
45 ..11.6 ..91.5 ..346.37 .5772.89 ..915
65 ..14.1 ..80 .....302.84 .5047.33 ..800
85 ..16.2 ..62.33 .235.96 .3932.71 ..623.3
the bypass opens at 85 psi.
MSD in-line
part # 2225
pros
goes in an easier to get to position
cons,
no bypass valve
cost
can only supply as mush fuel as the in-tank can provide
Voltage booster
By increasing the voltage to the pumps, you can also increase the flow. Can be used when changing pump is not desirible or when performance pump capacity has been reached.
Availible from
MSD (http://www.msdignition.com/tc_24.htm)
Dual Pumps
By doubling the pumps, you double the flow. Works best on large in-tank pumps. does require fabrication. dont forget to double up on the wiring too!
Fuel Rail
You can buy fuel rail blanks at www.atpturbo.com (http://www.atpturbo.com)
Equations
Maximum Horsepower with a Given Injector Size
(Flow Rate * No. of Injectors * 0.8) / (BSFC) = HP
Convert cfm to Estimated Injector Size
(CFM * 0.44298) / No. of Cylinders = Estimated Injector Size
Optimum Injector Size Equation:
(BHP * BSFC) / (No. of Injectors * 0.8) = Injector Size (Flow Rate)
Conversions: 1 atmosphere = 14.7 psi, 1 atmosphere = 101.3 kPa ,1 atmosphere = 1.013 BAR, 1 BAR = 14.51 psi Volume Conversions: [lbs/hour = Cubic centimetres (cc) per minute / 10.2] ; [cc per minute = lbs/hour x 10.2]
cc per minute = HP x 5 , HP (per injector) = cc per minute / 5 , HP = lbs per hour x 2.04
other reading
anthony hyde (http://wwwrsphysse.anu.edu.au/%7Eamh110/Technical_pages/bosch_403_fuel_injector.htm)
work in progress, part of a larger easy to find topics , will add info as needed
thanks to mike (thestartof) where most of this info came from, along w/ everyone else