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Old 10-02-2004, 09:11 PM   #1
n xntrx volvo
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Default fuel system upgrades faq

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

Injectors


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
Info for import injectors
Info for ford injectors
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.

-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.

-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

starian/ conquest
the mitsu starion/conquest motors have 80lb/hr injectors




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 in browntops
Non-turbo models, 4 x 10ohm resistors are required in line from the ecu.

Cleaning
Cruzin Performance
$11 per injector to be cleaned and flowed

RC Engineering, CA
$25 per injector to be cleaned and flowed. prob the best shop with the fastest turn around.

home ultrasonic cleaning

Accurate Technical Services in MI
$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

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

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

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
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Last edited by n xntrx volvo; 12-06-2004 at 05:38 AM..
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Old 10-02-2004, 09:38 PM   #2
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Good work there n xntrx. It's definately nice to have all that info in the one place (and nice that you include cc/min measurements because I can't process lb/hr measurements in my head. ).

I'm just wondering if anybody uses D Jet injectors as I'm sure they flow well (440cc or something???), in fact I'm sure I've read somewhere that they flow the same or even are the same as the modern day Bosch Motorsport injectors. Just wondering if anyone has any more info on them???

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Old 10-03-2004, 07:04 PM   #3
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<-thelostartof on a friends comp

lol dude that's right out of my thread and my pics .... let me try to get some new ones but yea those are mine haha i'll get some info on thise big CFI's posted to when i get back home

mike
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Old 10-03-2004, 07:12 PM   #4
n xntrx volvo
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just consol all of them, along w/ other fuel issues. wont work on till tommorrow, work on the abbrev today.
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Old 10-07-2004, 01:29 AM   #5
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The Dodge 4bar FPR only fits on the 700 style fuel rail, not the 240 style, though I'm not sure about newer 240s. Great thread!

John
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Old 10-07-2004, 11:23 AM   #6
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I made the dodge 4bar fpr fit on the old style (shepards crook) 240 fuel rail.
I cut the Nut that the stock FPR normally tightens into off of the stock fuel rail and I used some (3/8" ?) fuel hose to bridge the gap between the rail and the FPR.

I'm running the Dodge 4bar with the greentop(357) injectors with a resistor pack on NA lh2.0
Yes it is rich as a railroad tycoon at idle but my A/F ratio gauge says I start running stoich about the time I hit 15psi.
I also had my intank pump start to die on me so I replaced it with a new intank pump from a 740 turbo(hint, this was way cheaper than the new pump that autozone lists for the 240) I also swapped in a used inline pump off of a 740 turbo.
The 740 inline pump has different mounting brackets that hold it to the mounting cage than the 240 inline pump, a few zipties can fix this.


Peace,
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Old 10-07-2004, 12:57 PM   #7
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Quote:
Originally Posted by jpbturbo
I made the dodge 4bar fpr fit on the old style (shepards crook) 240 fuel rail.
I cut the Nut that the stock FPR normally tightens into off of the stock fuel rail and I used some (3/8" ?) fuel hose to bridge the gap between the rail and the FPR.
Dude! Great idea! And I've had this 4bar FPR sitting here for months, waiting for me to get a 740 fuel rail. I'll definately try it your way.

John
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Old 10-08-2004, 07:09 PM   #8
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thank you!
One question...
Are the Ford CFI injectors high or low impedence? and is there any way to tell by looking at them or the part # ? Thanks, Noah
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Old 10-08-2004, 07:10 PM   #9
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low impedence ... you mean i never told ya that ...
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Old 11-08-2004, 12:51 PM   #10
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I have found discrepancies to the CFI injector flow rates.

The V6 injectors, Bosch pn 0-280-150-402, is said to flow 338 cc/min (32.2 #/hr) at 3.0 bar, but the E3VE lists at 389 cc/min (37 #/hr) at 2.55 bar. The injectors I pulled this weekend from Ford V6 cars have both part numbers listed on them.

The V8 injectors (non-HO), Bosch pn 0-280-150-400, are said to flow 437 cc/min (41.6 #/hr) at 3.0 bar, but the E0SE lists at 485 cc/min (46.1 #/hr) at 2.30 bar. Likewise to the 3.8, the 5.0 injectors I pulled this weekend have both numbers on them.

The 403s you listed above are from a 5.0 HO. They flow 503/47.9 at 3.0 bar one one list, and 551/52.4 at 2.2 bar on another list

I've seen both numbers on the same list (Stan Weiss') and I've seen each number on separate lists, so which numbers would you go with? They're pretty big differences, especially once you correct for the difference in rated pressure.

Has anyone tested CFI injectors and verified a particular flow rate?

I'd also like to share a link - it's probably been posted here before, but I think it's relevant to this thread. http://www.supras.com/~riemer/sonict...rs/RCtech.html It's good reading and puts to rest a bunch of misconceptions.
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Old 11-08-2004, 12:59 PM   #11
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well for sure the 403's flow 59lb/hr @ 3bar(as tested by philip b i think)

and all mid 80's 5.0's were HO's weither they said it or not(had a lot of ford friends who kept telling me this)
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Old 11-08-2004, 01:06 PM   #12
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If HOs and non-HOs are the same, how come I just pulled -400 injectors from a pair of V8s this weekend? You'd think that if all 5.0s were HOs, they'd all need the -403 injectors, wouldn't you?

Maybe your Ford friends were talking about all Mustang motors being HOs? Otherwise, I think they're telling a joke.
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Old 11-08-2004, 03:45 PM   #13
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Application Year Ford number Bosch P/N Manu. Color gm/sec #/hr ohms

1.6 1983 E3EE-9F593-BA
Bosch Blue 1.76 14 2.25
1.6 1984 E4EE-9F593-AA
ND Blue 1.76 14 2.35
1.6 T/C 1984-85 E4EX-9F593-BA
Bosch Black 3 23 2.4
1.9 1985.5-86 E6EE-9F593-AB
Bosch White 2.45 19 2.25
2.3 T/C 1983 E3ZE-9F593-BA
Bosch Green 3.86 30 2.4
2.3 T/C 1984 E4ZE-9F593-AA
DKK Green 3.86 30 2.35
2.3 T/C 1985 E5ZE-9F593-AA
DKK Brown 4.41 35 2.35
2.3 T/C 1986 E5ZE-9F593-AB
DKK Brown 4.41 35 2.35
2.3 Truck 1985 E59E-9F593-AA
ND Gray 1.76 14 16.2
2.3 Truck 1986 E59E-9F593-AB
ND Gray 1.76 14 16.2
2.9 1986 E67C-9F593-A1B
Bosch Gray 1.76 14 14.5
3.0 1986 E59E-9F593-AB
ND Gray 1.76 14 16.2
3.0 1986 E67E-9F593-BB
Bosch Gray 1.76 14 14.5
3.8 CFI 1984-86 E3VE-9F593-A1A 0 280 150 402 Bosch Green 4.54 37 2.25
3.8 CFI 1984-86 -9F593-A2A
ND Green 4.54 37 2
5.0 CFI 1980 E0SE-9F593-AA 0 280 150 400 Bosch Blue 5.81 46 2.4
5.0 CFI 1983 E0SE-9F593-A1A 0 280 150 400 Bosch Blue 5.81 46 2.4
5.0 CFI 1983 E0SE-9F593-A2A
ND Blue 5.81 46 2
5.0 CFI 1984 E0SE-9F593-A1A 0 280 150 400 Bosch Blue 5.81 46 2.25
5.0 CFI 1984 E0SE-9F593-A2A
ND Blue 5.81 46 2
5.0 HO CFI 1984-85 E4ZE-9F593-CA 0 280 150 403 Bosch Gray 6.6 52 2.25
5.0 SEFI 1986 E59E-9F593-AB
ND Gray 1.76 14 16.2
5.0 SEFI 1986 E67E-9F593-BB
Bosch Gray 1.76 14 14.5
5.0 HO SEFI 1986 E6TE-9F593-AB
ND Gold 2.45 19 16.2
5.0 Truck 1985 E5TE-9F593-AA
Bosch Gold 2.45 19 15.5
5.0 Truck 1985 E5TE-9F593-AA
ND Gold 2.45 19 16.2
5.0 Truck 1985 E5TE-9F593-AA
DKK Gold 2.45 19 16.2
5.0 Truck 1986 E5TE-9F593-AB
DKK Gold 2.45 19 16.2
5.0 Truck 1986 E5TE-9F593-BB
Bosch Gold 2.45 19 14.5
2.3 HSC 1985-86 E43E-9F593-AC
Bosch Blue 7 56 1.4
2.3 HO HSC* 1985 E53E-9F593-AB
Bosch Green 8 64 1.4
2.3 HSC 1986 E53E-9F593-AB
Bosch Green 8 64 1.4
Vehicle
Injector Types Factory Flow Rating Notes
1990-'93 Geo Storm GSi Peak and Hold 222cc
1990-'93 Geo Storm 2+2 & Stylus S Saturated 222cc
1990-'93 Isuzu Impulse & Stylus XS Peak and Hold 222cc
1991-'92 Isuzu Impulse RS AWD Peak and Hold 322cc
1988-'91 Civic Si/CRX Si Peak and Hold 240cc
1992-'95 Civic Saturated 240cc
1996-'00 Civic dx cx and lx Saturated 190cc
1996-'00 Civic ex/si Saturated 240cc
1990-'91 Integra RS/LS/GS Peak and Hold 240cc
1992-'00 Integra LS/GS Saturated 240cc
1992-'96 Prelude Non-VTEC Peak and Hold 240cc
1992-'96 Prelude VTEC Peak and Hold 345cc
1997-up Prelude VTEC H22 Saturated 280cc
1991-up Sentra SE-R/200SX SE-R Saturated 265cc
1991-up MR2 Turbo Peak and Hold 440cc
1987-'92 Supra Turbo Peak and Hold 440cc
1993-up Supra non-Turbo Saturated 315cc
1993-up Supra Twin-Turbo Peak and Hold 550cc
2000-up Celica GT-S Saturated 310cc
1990-up Miata 1.6-liter Saturated 215cc
1993-up Miata 1.8-liter Saturated 240cc
1984-85 RX-7 195500-0900 Peak and Hold 680cc Orange Top
1986-87 RX-7 195500-1350 Peak and Hold 460cc Red Top
1986-87 RX-7 195500-1370 Peak and Hold 550cc Tan Top
1988 RX-7 195500-1350 Saturated 460cc Purple Top
1988 RX-7 195500-1370 Saturated 550cc Purple Top
1989-91 RX-7 195500-2010 Saturated 460cc Red Top
1989-91 RX-7 195500-2020 Saturated 550cc Purple Top
1993-up RX-7 Twin-Turbo Saturated Primary 550cc Secondary 850cc
1990-'96 300ZX Twin-Turbo Saturated 370cc
1991-up 3000GT/Dodge Stealth non-turbo Saturated 210cc
1991-up 3000GT VR-4/ Dodge Stealth R/T TT Peak and Hold 360cc
1989-up Eclipse/Laser/Talon Turbo/non-turbo Peak and Hold 450cc Blue Top(95+ Black top)
390cc Tan top
240cc Orange/pink Top
210cc Light Tan Top

Mitsubishi EVO Peak and Hold 510cc Yellow Top (1-3)
560cc Red top (4+)

1986-89 Ford turboCoupe Peak and Hold 35lb/hr Brown Top
30lb/hr Green Top

Last edited by n xntrx volvo; 12-05-2004 at 09:26 PM..
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Old 11-08-2004, 04:09 PM   #14
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Alright, there's yet another list, one that I haven't seen yet. Here's mine:

On this one you can look up the Bosch numbers and get one flow/pressure rating, and you can look up the Ford numbers and get something completely different:
http://users.erols.com/srweiss/tableifc.htm

Here you will find numbers that back up the Bosch numbers from the first table:
http://f1.grp.yahoofs.com/v1/UN6PQal...ow%20rates.pdf

And here you will find numbers that back up the Ford numbers from the first table:
http://f2.grp.yahoofs.com/v1/UN6PQSi.../injector2.pdf
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Old 12-05-2004, 09:21 PM   #15
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added that first link, its excelent!
fyi if you notice from the fuel pump charts that fuel pimp capacity goes down as pressure is raised.
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Old 12-06-2004, 04:13 AM   #16
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Awesome post!
Thanks for all the great information, especially in one post!
Time to make this either a sticky in this forum, or into the articles section where all can easily find it.

This is the kind of base we need!
Getting more in depth information like this on other upgrades like ignition, etc and into the articles/information forum would be awesome and very useful!
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Old 12-06-2004, 05:24 AM   #17
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Another awesome thread by n xntrx
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Old 12-06-2004, 06:07 AM   #18
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my CFI flowtesting from Cruzin Perf:




Test Results After Service

Date: 10-06-04
Vehicle:


Model: 195500-0424

Injector serial #: 410061-410064













Test pressure = 43.5 psiInjector No.
12345678
Test 1. Leak Down Test (Pass / Fail)PPPP
Test 2. Spray Pattern (Good / Fair / Poor)GGGG
Test 3. 30 Second Pulsed Flow Delivery (mL)595858580000
Test 4. 100mL Pulsed Volume1009999980000
Test 5. 10 Second Static Flow (mL)919093900000
Test 6. 100mL Static Flow9897100970000
Approximate pound-per-hour flow46.746.1847.7246.180000
Parts Replaced




Pintle CapsSealsO-RingsScreensHosesClips
0012400
Comments




Guess I should probably get the part numbers to make this more applicable eh?
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Old 12-06-2004, 09:26 AM   #19
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let me guess.... does the PN end in 400?
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Old 12-06-2004, 01:06 PM   #20
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Here are some slim line 4 hole Bosch injectors from Volvo that can be used.
The blue Bosch 0 280 155 830 391cc@3,8bar X70T5 -00>
The green Bosch 0 280 155 968 465cc@3,8bar S60 AWD-R-00> (also found at Mtsubishi Lancer EVO IV)

Both these injectors are high impedance 12,6 ohm.

I use the green 465cc injector myself @ 4bar nominal fuelpressure but they work fine with a total pressure above 6 bar
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Old 06-13-2005, 11:34 AM   #21
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Ok, so this is an old thread, but I found some info that may be helpful regarding the FPR's. Found on another site I don't have a link to, but here's the info anyway.

Quote:
Doing some research the other night looking for adjustable FPRs I found the illusive 4 bar FPR.
Little did I know old Dodges, Daytona's, Caravans, Omnis, New Yorkers, Spirits & anything sporting the L4 2.2L 135 cid Turbo Engine had these 4 bar FPRs stock (OEM).
I just did a search for a 1988 Dodge Daytona Shelby & I compiled a list of companies that make this Bosch Style 4 Bar FPR.
The Mopar part # 4306015 437 (found at any local dealer)
Bosch Unit # 280 160 260
AC Delco # 17119253/or 217-171
Standard Motor Products # PR7
KEM # 143-602
Tomco EMIS # 21019
Napa Echlin # CRB219578
Borg Warner # 22823
GP Sorenson # 800121
Might make life a little easier to find a normal 4-bar.
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Old 06-13-2005, 09:45 PM   #22
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Quote:
Originally Posted by gsellstr
Ok, so this is an old thread, but I found some info that may be helpful regarding the FPR's. Found on another site I don't have a link to, but here's the info anyway.



Might make life a little easier to find a normal 4-bar.
Actually, I have been looking at this myself. Summitracing has a regulator that goes on the Mopar cars that is adjustable. They go to about 4.4 bar. The only thing I see with them is attaching a hose barb to the end of it to attach to the return line.
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Old 07-27-2006, 03:15 AM   #23
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This is such a great amount of information. It's definately a help for me.
James
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Old 07-30-2006, 02:40 AM   #24
740freak
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Hi,

I need to change all my fuel line. Do you think its a good way to upgrade all the fuel system by the same time?

And by the way.. whats is the size fuel line may i chage for a good upgrade?

thanks !
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Old 05-27-2007, 07:05 PM   #25
palamut
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i have a 2.0 lpt 163 hp engine and i am thinking to use s60R's injectors on my car is there any impedence or ohm differences ? i use a walbro fuel pump and a 3.5 bar fuel pressure regulator and my standard fuel rail i have a custom turbo kit built and a custom chip will be used with perfectpower smt 6 piggyback computer

Thanks for all this good information for all the users
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