just wondering if anyone could recommend a boost setup for a very mild street setup on a 96 cavalier 2.2L OHV. i am definatelly not looking to race, but at the same time i dont want to be dusted.
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well..you see the 95-97 have these stupid fuel injectors that their is no higher flow option to replace it becuase of their placment, meaning we pretty much cant run much boost without running way too lean and blowing the motor...i though i heard of somone running 5 psi but i think that would be pushing it... i been looking into it too but pretty much came to the conclusion id have to do some sorta motor swap
96 cavi'/WI j's
THere are other options for the 95-97 2.2 ohv engines. It is probably more expensive though. If you search you will come up with other ways such as an EIC, MF2, or even a fuel rail swap. I don't know much about any of these ways to compensate for the fuel issues but I do know that some people have conquered it.
I'm running 7 psi on my stock 2.2l with the right turbo and a huge intercooler like mine you can do it.
horsepower is how hard you hit the wall, Torque is how far you push the wall with you
well yeah their are other options like a fuel rail swap but if he has to ask about a "mild set up" then i highly doubt he will be looking into that much work
96 cavi'/WI j's
A good turbo setup takes work. Doesn't matter if it's mild or wild, it's not "bolt in." I'm running 7 psi on stock 2.2 internals non intercooled. It can be done with the right tools.
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i am definatelly willing to do the work, it would however be nice to have somebody who shared my enthusiasm for the genre... all the other j- owners around here are @!#$s...
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yeah i also have a 96 2.2 and want to go boost help us out thanx if u can help me
aim: chevyTUNER96
I dont think anyone here can help you out as much as researching things on your own would do.
Look at how some people are increasing their fuel delivery, then make an educated guess on which system would be best for your needs.
EIC's, and FMU's, are bandaid methods, that some have had success with.
anyway, do your own research, you'll learn a lot more then you ever thought you needed.
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Just don't press 9 on a stock fuel system
You would be fine at 5psi with a band-aid FPR, I think you could do 8 or 9 with extra injectors and an EIC. Anything over that and you should grab a spare intake manifold and a 2200 fuel rail, take it to a fabricator, and have them port out the stock injector housings and weld in some bosch-style injector bungs.
But yeah, for a mild street setup (5-6 psi) you won't have to do anything drastic. Maybe give Cav Connection a call.
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its not just the conversion you have to do, as I believe you'll also need something like an SAFC-II to help control the idle of the injectors even more.
ForcedFire spent abotu $1000 in machining on his intake manifold to convert to top feed.
I'm sure I could do it cheaper as I have a machine shop at work.
Is it possible to bore the stock injector size out to fit top feeds?
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You would be fine at 5psi with a band-aid FPR,
That's really pushing it. The injectors will end up way over maximum rated pressure in order to deliver enough fuel when engine rpm climbs.
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ForcedFire spent abotu $1000 in machining on his intake manifold to convert to top feed.
Yes, but there's someone here who spent much less to have the machining done to his manifold. It's in the archives.
Read me
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Obviously after the conversion, you would need something to control the opening of the injectors (if you decided to go with larger injectors, which is really the point I guess), but that's the easy part.
VTLoki did a good job, but instead of having to machine the bores perfectly (3 radius), I would just weld in some pre-made bungs (availible at SDSEFI.com)
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to weld in those bungs would take some heavy grinding of the manifold, would it not?
and to have them line up perfectly at the right angle? Probably hard to do.
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I also am running a 2.2 on stock injectors (14lb i think) on 5-7 psi no problems so far . I've heard of others running 8psi for extended periods of time with no major malfunctions. However like everyone else will tell you this setup will put large amounts of stress on your fuel pump and run the risk of cliping an injector. So it all depends on what your goals are and how much money and time your willing to sacrifice on your setup to get the boost you want and the reliability to go with it . Good luck.
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to weld in those bungs would take some heavy grinding of the manifold, would it not?
We'd need to get some dimensions to know for sure. Another option might be machining the OD of the bung slightly. VTLoki machined the manifold enough for the injector body to fit in the old fuel rail, but that's not such a critical dimension that a big drill bit can't be used.
As far as aligning the injectors perfectly with the ports, you'd be surprised how much some of the OE stuff is off from "perfect." Don't forget that the 2.2 Cavalier, cool as it is, is not the most important vehicle GM makes. Close is close enough for these cars.
I have a spare manifold or two here for checking if someone were to find the OD for those injector bungs.
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stevefire wrote:to weld in those bungs would take some heavy grinding of the manifold, would it not?
and to have them line up perfectly at the right angle? Probably hard to do.
Sorry, I just checked that site again, and those are new bungs. I emailed them, and they don't offer the old ones anymore. These would be different. My plan's gone.
The angles on the OEM ports, and the OEM 2200 fuel rail are almost identical. One of the sets I have looks like one of the injectors might be spaced over a few millimeters, but not much. I would have just drilled out the stock bores, and welded in the new bungs, but alas, no more.
I think VTLoki's route may be the most cost-efficient now. What was the special machine he needed? anyone know?
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Injector bungs aren't anything real special. They used to be worth gold, but the prices have dropped almost as fast as gas prices have risen. You might even find a set of 'em in Summitt racing or on Ebay.
First links from Google search for "injector bung"
linky
linky linky
These are priced right
a 2" long version here
I'm sure something can be done with one of these.
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Forgot to add that the Holley page has instructions for installing their product. They require a 27/32" (0.84375") hole to place the bung in. Looking through VTLoki's posts when he was making his manifold, the injector hole in the rail is .991", slightly over 1/8" larger. Food for thought, is all.
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