Well, I've been working on converting my 95 2.2 side feed injector system into a top feed in preparation for my turbo that will be going on. I finished saturday, but only got to take pics today, and I painted it monday.
I'm using the 98 top feed injectors for now since their only a little bigger, 17 vs 19lbs/hr. Also, to mount the 98 2200 fuel rail, which is what i used because it align's perfect to the 95 injector holes, i drilled and tapped holes into the manifold metal. used some bolts from advance auto parts to secure it. Now, those mounts did need to be bent, and heated, and bent many many many times before we got it to even be flush, then we marked holes, and did the drilling and tapping. man, i swear, lotsa time with a torch to get it right.
As for the manifold accepting the top feed injectors, i had to get those holes machined out. Now, to get it done, i had a machine shop do it, and not any machine shop could do it. I checked like 8 different places and they couldn't do it. I'll ask my machinist guy what the machine is called, that made it so special. anyways. after that, the injectors slid in. I mounted them at the same depth as the old ones. That may be a mistake, but we'll see once i get the car running. Anyone know how far from the intake runners the 2200 injectors are? I tried to find out, before it was machined but couldn't. I have a pic below, tell me what you'll think? The only problem could be if it sprays into the metal, and doesn't fully vaporize the fuel.
As for the fuel pressure regulator, i'm using an aftermarket adjustable one, thats why u see a brass fitting JB welded into where the original one goes, i'll have a fuel line from that run to the FPR.
I've re-wired the harness clips to accept these new injectors, but enough of the details, onto the pics.
side view:
top of intake runners:
View of the injectors in the holes from the bottom, close enough to the runners?
Different angle
Well, what do you'll think?
If my short block ever arrives, i'll have tons of pics of an engine install coming up. in a new thread.
agreed excellent job
04 sunfire auto, mid 15's n/a, and still going
i might open the area around the injectors to help them spray better
but looks pretty good other wise
Very nice!
15.3 @ 89.97mph, 14's on the way?
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'01 SFGT springs $50CAN
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that is very very nice man. congrats on the job. if i wasn't planning on swapping i would follow up on that job myself.
I was a retard, and now I'm permanently banned.
I agree. Nice job. Very clean!
You should be fine. You'll have more trouble if you're too close to the intake valve than if you're too far away. Some of the early efi intakes didn't even aim the injectors at an optimum angle, and they still worked well. And considering that I'm using a TBI injector which has a completely different pattern, and that the car runs well, I don't see where you'll have too much of a problem.
Did the machinist have to alter the bore so the bottom of the injector would seal?
You might look for a set of used stock LT1 injectors or turbo Sunbird injectors when you need to step up to more fuel.
I've obtained a lathe so I can start playing around making bushings that will allow top feed injectors to be fitted into a 2.2 manifold. I figured that I could open the holes up more than needed then spin up some bushings to make up the difference. It didn't look to me like a special machine was needed to do the job. I figured a bridgeport would work fine.
-->Slow
VERY NICE!!!
did you have to have the original injector bosses welded up for reboring? Or, did they require a larger diameter hole then the original bosses? Did you have to weld up the original fuel rail at all?
please keep us posted!
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damn I need an edit button.
slowolej, that is a very good idea, I actually never thought of doing that. (making bosses to weld into the manifold)
That would make finding the proper angle a heck of a lot easier.
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i found this route, machining the intake less hassel for me. I didn't want to bother with any welding. I had to do no welding for mine, but i did have a torch to mold and shape those mounting brackets on the fuel rail. I did JB weld that fuel fitting in, cause it was brass, and didn't want to weld brass.
I just machined the current hole bigger.
slowolej, he did alter the lower hole as well. there were actually 3 diameters. one forthe larger top , the bottom, but in the middle, on the injector, there's like a metal protruding. He machined that diameter too.
MAn that looks tight, almost makes me want to convert to the older 2.2 intake to have a better setup than the plastic, hell that almost looks stock. Great Job.
Mike
1992 GMC Sonoma GT #492. Oh, Its just a stock V6!
1999 Cavalier Coupe, daily driver, 2200/M5. Mods and pics are in my registry.
Fully built turbo 2200 in progress, should be installed very soon. Will post details as they happen.
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Im premium since January, but why doesnt it say that?????
I've got some pics of the modification process. Just a few of what it looked like before. Make me appreciate the finished product a little more.
This is us heating it up, and getting ready to bend it.
This was only after like one or a few bends. not even close, you'll notice the left bracket hasn't been modified at all yet, thats what the original angle is, and when its done you see how much it had to bend.
Thats all.
wow, thats pretty cool.
how did the machine shop get the proper angle for the injectors to mate with both the new bore on the manifold and the 2200 fuel rail?
do you think its possible to reweld some brackets onto that fuel rail without damaging anything?
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Well, thats the beauty of the 2200 fuel rail, the angles of the bore match perfectly to what the angle was previously. my machine guy didn't change the angle on the intake manifold, he just made the holes larger.
As for welding on a bracket, i though of that too, but then its such a thin piece of steel, and fuel needs to flow through there... i figured it'd be a little safer to just bend these. probably a little more work, but i'd rather be safe then sorry.
cause if the penetrations is too much, maybe it will obstruct the flow of the fuel, i dunno, i'm not a welder, my buddy would have did it if i went that route. He's a certified welder.
Just an update, the fuel rail had some crack in it when I pressurized it, and we ended up welding some shut, and also brazing a lot of brass onto the whole area where the cracks were. The cracks probably came from the bending of the bracket, since it was right next to that.
Its all fixed now. I'll try to get updated pics, but its ugly, that red paint didn't stand up to fuel when it squirted everywhere, and the heat from welding wasn't friendly much, lol.
hey vtLoki give me an e-mail I want to talk to you about this
horsepower is how hard you hit the wall, Torque is how far you push the wall with you
I just wanted to provide some updates on this conversion. The conversion works great, but in retrospect, i wouldn't use jb-weld if I did it again. Just take a torch, and braze(melt) some brass in the fitting to secure the return line. Also, for the brackets, it seems all the heating and shaping of the brackets caused micro-fractures in the fuel rail. I also needed to melt some brass over those areas too. Only took a few more hours to fix, and then it worked fine.
I also found that when I put the throttle body onto the intake, the throttle plate butterfly valve did not open more then 5% before it hit the new fuel rail. I machined a new spacer on a CNC mill, about 1" think, and that fixed the problem. It doesn't hit the hood either. The spacer is made from t-6061 aluminum. Aircraft quality!!! hehe. I intensionally made the spacer larger then the gasket so there was a little bit of over hang, and it would act as a heatsink, and perhaps cool off the metal a little bit.
Here are a few pictures of the spacer:
holy cow very nice! i like that spacer!
Im sure Madjack will be in soon to express his love for this. It looks amazing. Very nice peice. I would like to have one like that in a 3/4" thickness.
steve white wrote:Im sure Madjack will be in soon to express his love for this. It looks amazing. Very nice peice. I would like to have one like that in a 3/4" thickness.
And probably to share his homemade spacer as well
fortune cookie say: better a delay than a disaster
how much would that cost to do if you did it for me
i have no skill in this what so ever
Looks good man. Great job most people cant get this done...
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