Flow #'s are in for the 60 LB High Impedence Injectors

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turbov6man

Just one more pound of boost never hurt anybody!!!
Joined
Jun 3, 2001
Messages
154
Just recently purchased 3 sets of the new high impedence 60 lb injectors from Mike at Full Throttle, and I was interested in what they were actually flowing. So I sent them to Precision Turbo for flow matching.

The results were:
55.5, 55.5, 56.2, 55.2, 55.6, 55.8, 57.7, 57.5, 57.5

57.5, 57.3, 57.8, 56.7, 57.1, 57.1, 56.6, 56.5, 56.2

All these injectors were flowed at 90% Duty Cycle at 6000 rpm.

The varience between the highest and lowest number is 5.5%.

Precision sent them back sorted so that the sets were matched as close as possible for the best overall results. Being able to flow 3 sets allowed them to keep the sets close. I am concerned that I could have gotten a set and ended up putting a 55.2 with a 57.8. This could have made for some tuning issues at the least.
 
Originally posted by turbov6man
This could have made for some tuning issues at the least.

If you got both the erratic high, and low one in the same batch. That would be what 2 to the 15th power?, just off hand wouldn't that equate to a less then a one in a million possibility. You could risk that much in the odds of them being thrown off kilter in just shipping them, at that rate.

Interesting to note also is that they all flowed to the high side of spec.. 90%DC in batch fire mode would be 54 PPH.
 
If these results are typical (and that is a big assumption) then there is a 1 in 18 chance of getting the high or low. In a set of 6 you have 6 shots at it for the first and 5 for the second so the odds of getting both are 6/18 x 5/17 or 30/306. Basically 1 in 10.

Tom
 
I think I just calculated the odds of getting the high/low by pulling the 6 out of a set of 18 that contained both. Probably not correct.

Sorry about that.

Tom
 
When I first got these I was told they were all very close. We pulled 10 random units and they were all close. I will do it again I just got another shipment and see what is up. I will post the results but it will take a few days we are swamped
Mike
 
I agree that the possibility of getting a set that are that far apart is unlikely, just wanted to show what the actual flow #'s were. Keep in mind that only 18 were flowed, and may or maynot be an indicator of the characteristics for these injectors. Just showing the statistics of the 3 sets recently purchased.

We also can now match the injectors to the cylinders that we would like to have them in, i.e. the richest ones in 3, 5, and 6. Since these are the notorious lean ones for the buicks.

The overall #'s for the injectors were great, and show the ability of them to flow at or above the 60 lbs.

But for such a large high impedence injector that works with the factory ECM, the price is a GREAT DEAL!!!
 
Originally posted by turbov6man
Just recently purchased 3 sets of the new high impedence 60 lb injectors from Mike at Full Throttle, and I was interested in what they were actually flowing. So I sent them to Precision Turbo for flow matching.

The results were:
55.5, 55.5, 56.2, 55.2, 55.6, 55.8, 57.7, 57.5, 57.5

57.5, 57.3, 57.8, 56.7, 57.1, 57.1, 56.6, 56.5, 56.2

All these injectors were flowed at 90% Duty Cycle at 6000 rpm.

The varience between the highest and lowest number is 5.5%.

Precision sent them back sorted so that the sets were matched as close as possible for the best overall results. Being able to flow 3 sets allowed them to keep the sets close. I am concerned that I could have gotten a set and ended up putting a 55.2 with a 57.8. This could have made for some tuning issues at the least.


My personnal opinion is that ALL OF THESE INJECTORS SHOULD BE FLOW MATCHED BEFORE USING.

The First set of Six that I received data on here at PTE had a High of 58.8# and the Low was 54.8# that was 7%+.

The 18 (3 sets that turbov6man)above referenced. The Low to High aprox. 5.5%

I'm not saying that they do not flow the advertisted rating.

I'm saying these injectors are not within a specific tolerance from
one injector to another.

If you are comfortable with this type of tolerance then there's no problem, but I sure wouldn't trust them In my engine, unless fuel matched.

Sorry Im sure I am making very unpopular statements here, but the truth is in the Data.
 
Re: Re: Flow #'s are in for the 60 LB High Impedence Injectors

Originally posted by Joe Lubrant
My personnal opinion is that ALL OF THESE INJECTORS SHOULD BE FLOW MATCHED BEFORE USING.

The First set of Six that I received data on here at PTE had a High of 58.8# and the Low was 54.8# that was 7%+.

The 18 (3 sets that turbov6man)above referenced. The Low to High aprox. 5.5%

I'm not saying that they do not flow the advertisted rating.

I'm saying these injectors are not within a specific tolerance from
one injector to another.

If you are comfortable with this type of tolerance then there's no problem, but I sure wouldn't trust them In my engine, unless fuel matched.

Sorry Im sure I am making very unpopular statements here, but the truth is in the Data.


For a racing engine, and deep pockets, sure why not. For Joe Average, can you document any real advantage?.

And if I worked at a shop where we did injector flow testing I'm sure I would run a matched set just for grins.

It seems that the oem specs have worked and worked well for billions of miles of actual use.

And while drawing parts out of the bin is a 50/50 change for any one given item, it's not just 1 in 6, unless the sampling is only for that lot, for the odds of getting a low flow one. Picking a high and an absolute low out of 16 at random is just a one in a million chance (I'll gladly summit to correction by someone familiar with true credentials in probability analayze).
 
I certainly can't say what is acceptable tolerance, but the 1 in a million doesn't even seem to be applicable. That would apply to getting the single worst case variation out of a batch of 1 million injectors. Pulling any 6 would reduce it to 1 in 166,667.

I do not believe that my calculation is that far off. I'm just not sure if the second injector is 5/17 or 5/18. I also do not know the calc to determine the statistical tolerance of such a small sample.

Tom
 
Re: Re: Flow #'s are in for the 60 LB High Impedence Injectors

Originally posted by Joe Lubrant
My personnal opinion is that ALL OF THESE INJECTORS SHOULD BE FLOW MATCHED BEFORE USING.

The First set of Six that I received data on here at PTE had a High of 58.8# and the Low was 54.8# that was 7%+.

The 18 (3 sets that turbov6man)above referenced. The Low to High aprox. 5.5%

I'm not saying that they do not flow the advertisted rating.

I'm saying these injectors are not within a specific tolerance from
one injector to another.

If you are comfortable with this type of tolerance then there's no problem, but I sure wouldn't trust them In my engine, unless fuel matched.

Sorry Im sure I am making very unpopular statements here, but the truth is in the Data.

I would LOVE to know the details of the flow tests quoted (working fluid, differential pressure, etc) ... I have the results spreadsheet here that were done over a sample of 4656 injectors(done by Mercury Marine with the injectors on a dyno )

The test set was with:

Static Target 6.373 g/s
Dynamic Target 12.601 mg/P

Pressure 200 kPa
PW 2.5 ms
Fluid Viscor

Stat Limits ± 4%
Dyn Limits ± 4%

They varied less than 3% across the board (most around 1%). There were 2 injectors that were at 4% in the sample. These things are done at extremely high volumes and are used in many of Mercury's products.

Here's an example of one of the worst ones in the sheet I could find:

Serial number 2038A0844
Static 6.131 g/s
Dynamic 12.732 mg/s
Stat Err: -3.80%
Dyn Err: 1.04%

Here is the median sample:

Serial Number: 2038B12565
Stat: 6.436 g/s
Dyn: 12.612 mg/P
Stat Err: 0.99%
Dyn Err: 0.09%

Not to say that I've personally seen it done with my own two eyes, but with the amount of money Mercury spends on this kind of thing for high performance Marine use, I tend to believe the spreadsheet. I'm wondering what the difference in test methodology is, or if it's something in the batch or what?

Basically, everything I've seen personally tested with them (including a 940 HP BBC) has been great with these injectors ... better throttle response, power, and better EGTs from cylinder to cylinder. I haven't personally flowed any of them, but from seeing them running in several motors now I'm not sure what's up with the flow numbers being reported.

Also, they use these injectors (in pairs per cylinder) in the new twin screwcharger Mercury 1050 blown marine motor ($130K each) ... the 1050 number reflects the horsepower, BTW! <*They are sweet motors based on the GM 8100*>
 
I would think this is an issue for all those running the power plate on the stock ecm.

If you are not, than just take the fat ones and run them from cylinder 6 to 1 and no worries.

But it appears as if you need to flow these which is another $60 on the consumers end. The 57lbs are already matched at Racetronix for you so I see no need for power plate users to run these if this data is consistent.
 
From what I've seen in the ones I have, if I was going to worry about wanting to further fine tune the motor, then I'd want 6 WBs, and individual PW compensation on all 6 cylinders at 200 RPM increments to really dial things in. Less then that, and your just guessing with really going on anyway.

IMO, if your going to worry about things to the nat's whisker then fine, let's uniformly worry about it. Injectors are just part of the cyliner to cylinder variances. We can even worry about how much the cam shaft twists under load from 1,500 RPM to 5,000 RPM.

Like I said earlier, in a full on race engine, ya, go ahead an spend your money where you best see fit. But, on a street engine, where these are most likely to be used, there are so many other issues that you can get lost in details and miss the bigger picture.

And the 5% when the injectors are used in a static mode, might be of a much bigger concern, then say in a motor propperly injector'd. Since in a properly sized motor there is always going to be the matter of the ecm calulation always being rounded off slightly anyway. Not to mention the differences in reversion from cylinder to cylinder, and that effect on the wet flow portion of the injectors delivery. If you look around inside the intake there is some gas staining, from gas being blown around in the plenum anyway. So there is some averaging being done on a mechanical level anyway, with the stock based manifolding.
 
Originally posted by DR.BOOSTER
I would think this is an issue for all those running the power plate on the stock ecm.

If you are not, than just take the fat ones and run them from cylinder 6 to 1 and no worries.

If they are not flowed, one would not be able to identify the fat ones.

I believe that the published power plate specs are still 10% variation with the stock plenum, and 5% with Precision's.

Tom
 
Re: Re: Re: Flow #'s are in for the 60 LB High Impedence Injectors

Originally posted by bruce
For a racing engine, and deep pockets, sure why not. For Joe Average, can you document any real advantage?.

And if I worked at a shop where we did injector flow testing I'm sure I would run a matched set just for grins.

It seems that the oem specs have worked and worked well for billions of miles of actual use.

And while drawing parts out of the bin is a 50/50 change for any one given item, it's not just 1 in 6, unless the sampling is only for that lot, for the odds of getting a low flow one. Picking a high and an absolute low out of 16 at random is just a one in a million chance (I'll gladly summit to correction by someone familiar with true credentials in probability analayze).


:cool: Well lets see Bruce... My statements in the above post about flow matching these injectors was stated as "MY PERSONNAL OPINION"

As for flowing the sets for a GRIN , If your engine made enough power to use 60# injectors and they varied as much as 7%+ , then you can change your GRIN to Laughter when you smoke a gasket, piston or worse. This can and is a serious issue.

Most suppliers fow match all Injectors 50# & Over. Why would it be any different for a NEW injector on the scene without any real history or true data to be subjected to the same scutiny?

As for AVERAGE Joe"s..... most average Joes run stock, 30, 36, or 42.5# Injectors that have been proven to be within 2%-3% in Flow. NO CREDENTIALS ON ANALAZATION, but 2-3% of small injectors exhibit small changes in flow differences. So the OEM statement doesn't prove a D_M thing as we are dealing with injectors more than 2X the stocker oem's. nuff said.

Save the analytic stuff on whats your chance of getting this or that, all I can tell you is, I have seen actual flow data on 24 injectors, and if they were not matched up as sets on a car, there would be issues.

Gamble if you must!!! .......I guess if $10-15 an Injector flow is to much for peace of mind or to find 1 or 2 injectors need to be exchanged.

I would not want someone to GAMBLE on ODDS, you can play your #'s game, but with the manifold distribution issues we have with the T/R's, Injector flow differences are very important.

In closing as I said MY OPINIONS, based on known data, and experiences with car/engines that have had Injector flow differentials of an unacceptable level.
 
Joe,

There will always be those who put their pocketbook in front of common sense. I could not agree with you more on your posted statements.

As I have posted before Siemens spec on the Deka 4 (aka Mototron) injectors is +/-5% and it gets shipped. This is the same spec as all other Siemens and Delphi product.

Putting the +/-5% spec aside I have come across dud injectors from both Siemens and Delphi which I keep here on the shelf as a constant reminder of what might end up going out the door if it were not for companies such as PTE and Racetronix screening the injectors.

I have found that the better percentage of Delphi disc injectors fall within a 3% window as well.

Jack :cool:
Racetronix
 
Re: Re: Re: Re: Flow #'s are in for the 60 LB High Impedence Injectors

Originally posted by Joe Lubrant
:cool: Well lets see Bruce... My statements in the above post about flow matching these injectors was stated as "MY PERSONNAL OPINION"

As for flowing the sets for a GRIN , If your engine made enough power to use 60# injectors and they varied as much as 7%+ , then you can change your GRIN to Laughter when you smoke a gasket, piston or worse. This can and is a serious issue.

Most suppliers fow match all Injectors 50# & Over. Why would it be any different for a NEW injector on the scene without any real history or true data to be subjected to the same scutiny?

As for AVERAGE Joe"s..... most average Joes run stock, 30, 36, or 42.5# Injectors that have been proven to be within 2%-3% in Flow. NO CREDENTIALS ON ANALAZATION, but 2-3% of small injectors exhibit small changes in flow differences. So the OEM statement doesn't prove a D_M thing as we are dealing with injectors more than 2X the stocker oem's. nuff said.

Save the analytic stuff on whats your chance of getting this or that, all I can tell you is, I have seen actual flow data on 24 injectors, and if they were not matched up as sets on a car, there would be issues.

Gamble if you must!!! .......I guess if $10-15 an Injector flow is to much for peace of mind or to find 1 or 2 injectors need to be exchanged.

I would not want someone to GAMBLE on ODDS, you can play your #'s game, but with the manifold distribution issues we have with the T/R's, Injector flow differences are very important.

In closing as I said MY OPINIONS, based on known data, and experiences with car/engines that have had Injector flow differentials of an unacceptable level.

I like how you totally ignored the cylinder trim issue if you really wanted to be button on.
And since you mentioned the air flow differences, then why don't you mandate buying a new plenum with ever set of injectors?. It's only money.

You're gambling every time you drive to work. Odds are you'll make it, but no guarantees. Marketing on the fears of others is a common tactic thou.

And where is this data about at what level of flow differences makes a difference?, or is that just opinion?.

And if the flow is sooo important then why don't you match each set perfectly?. Not close, perfectly.

Like I said there are errors that are beyond anyone's control, that will impact things just as directly as injector flow, and when given any set of errors stack up in any particular way, there can be problems.

And it would seem your stuck on the need thing, and I'd venture a guess you still sticking with your old calc's and ignoring the AE functions, for injector sizing.

Like I said, if I worked at a place where we did injector flow testing I'd do it. Given the specs Ken did from an oem, I'll stick with that info.. Or are you going to infer that your testing procedures are better then those at the oem level?.

And this is just about the 60s, which are a different animal then the 55s and larger that did alledgedly suffer from poorer quality controls.

I bought a set of new injectors from PT+E and they're maked as a low of 48.8 and a high of 49. And these are supposed to be 55 PPH. If your using the same testing them they ought to be 49.5s at a 90% DC, and that makes them all under spec.. Tested 10/03.
By the same token the min would be 54s for the 60s, and they're all well above that.

I'll just ignore your comment where you start exaggerating with the 7% number, and you go off on a tangent.
 
Bruce... you are way off the mark on this topic.

The QC on the Deka one series is as good as it gets as they are all hand assembled and tested in Siemens' test lab / low volume dept. The Deka 4 injectors are made on the OE assembly line.

I have injectors here that flow outside the factory +/-5% spec and some that are so far off you wonder what the hell they were doing on the assembly line! Granted these are rare but would you want one of these injectors ending up in your batch? Mute point.

Some of your statements like "And if the flow is sooo important then why don't you match each set perfectly?. Not close, perfectly.
" are ridiculous. You know why two injectors will never be exactly the same just as there are no two diamonds, ball bearings or resistors that are EXACTLY the same. Everything has a tolerance. An acceptable tolerance for a factory motor vs. one that is being pushed to the edge are totally different. One injector 3% down will cause that cylinder to knock (depending on the hole it is in) and cause the timing to be retarded thereby impeding the max HP of all cylinders. TR owners do not have the luxury of having a LS1 PCM with individual cylinder knock & timing control & diagnostics.

If today's injector tolerances were not a major issue then why would companies such as Delphi and Siemens invest millions of dollars to improve the technology? This is done to maximize performance and minimize emissions. Flow-matching is too costly for an OE so the technology must be improved the reduce the variance off the line.

Jack :cool:
Racetronix
 
Originally posted by Racetronix
Bruce... you are way off the mark on this topic.

The QC on the Deka one series is as good as it gets as they are all hand assembled and tested in Siemens' test lab / low volume dept. The Deka 4 injectors are made on the OE assembly line.

I have injectors here that flow outside the factory +/-5% spec and some that are so far off you wonder what the hell they were doing on the assembly line! Granted these are rare but would you want one of these injectors ending up in your batch? Mute point.

Some of your statements like "And if the flow is sooo important then why don't you match each set perfectly?. Not close, perfectly.
" are ridiculous. You know why two injectors will never be exactly the same just as there are no two diamonds, ball bearings or resistors that are EXACTLY the same. Everything has a tolerance. An acceptable tolerance for a factory motor vs. one that is being pushed to the edge are totally different. One injector 3% down will cause that cylinder to knock (depending on the hole it is in) and cause the timing to be retarded thereby impeding the max HP of all cylinders. TR owners do not have the luxury of having a LS1 PCM with individual cylinder knock & timing control & diagnostics.

If today's injector tolerances were not a major issue then why would companies such as Delphi and Siemens invest millions of dollars to improve the technology? This is done to maximize performance and minimize emissions. Flow-matching is too costly for an OE so the technology must be improved the reduce the variance off the line.

Jack :cool:
Racetronix

So what do you call close enough?.
In the sampling Ken quoted as done by an oem, they were pretty close, IMO.

And with the addition spending the oems are constantly doing, are you stating they are no better then what they were decades ago?.

Got any specs on what of variance you'll guarnantee as being lean proof?. ie pligs will read identically from cylinder to cylinder?.

Are you going to state as fact that manifolding isn't just as big of issue?. How about errors in the ECM?.
How about adressing the wet flow in the manifold?
I see those issues are being ignored by you and Joe.

If you want to discuss balance, then it goes much further then just the injectors, and some are worse then others, I mean that's only obvious. But, the issue is what's being reported, and what level is acceptible. And lets get back to the original issue, it took 16 to get the 5% variance, and according to the numbers that I recall Jason posting about the manifold's airflow, it was further off then the 5.5%. At that rate, the manifold should get alot more and immediate atttention then the injectors. Yet, there are guys going pretty quick with the stock manifolds, with all it's faults.

And these are used in according to Ken $130K engines. I would tend to believe at that level, they going to make sure things are correct. Or are you going to say Mercury Marine is just hoping the injectors are close enough?.

And if folks want individual cylinder Knock sensing, all they need do is get a K+S Knockguard.

And like I said a full on racing effort is another matter. For them tuning to the detonation threshold is mandatory, for the street guys, doing that is just a matter of time before preignition and/or a bad tank of gas does em in anyway.

Gotta remember the K/S only is designed to catch detonation, not pre-ignition. And it's not to hard to change the acoustic signature so that the K/S misses some of the detonation anyway.

Needless to say, I also read my plugs fairly often, and if I saw one cylinder was constantly reading lean and another one rich, I wouldn't have a problem with swapping the two injectors to see if there was a problem.

I can only say, the 6 in my car, are leaving the plugs identically colored, as far as I can see.

Hmm, maybe batch fire has the added advantage of wetting the manifold/plenum more, and giving a better average AFR for the cylinders to draw against....
 
Originally posted by bruce
So what do you call close enough?.
In the sampling Ken quoted as done by an oem, they were pretty close, IMO.

And with the addition spending the oems are constantly doing, are you stating they are no better then what they were decades ago?.

Got any specs on what of variance you'll guarnantee as being lean proof?. ie pligs will read identically from cylinder to cylinder?.

Are you going to state as fact that manifolding isn't just as big of issue?. How about errors in the ECM?.
How about adressing the wet flow in the manifold?
I see those issues are being ignored by you and Joe.

If you want to discuss balance, then it goes much further then just the injectors, and some are worse then others, I mean that's only obvious. But, the issue is what's being reported, and what level is acceptible. And lets get back to the original issue, it took 16 to get the 5% variance, and according to the numbers that I recall Jason posting about the manifold's airflow, it was further off then the 5.5%. At that rate, the manifold should get alot more and immediate atttention then the injectors. Yet, there are guys going pretty quick with the stock manifolds, with all it's faults.

And these are used in according to Ken $130K engines. I would tend to believe at that level, they going to make sure things are correct. Or are you going to say Mercury Marine is just hoping the injectors are close enough?.

And if folks want individual cylinder Knock sensing, all they need do is get a K+S Knockguard.

And like I said a full on racing effort is another matter. For them tuning to the detonation threshold is mandatory, for the street guys, doing that is just a matter of time before preignition and/or a bad tank of gas does em in anyway.

Gotta remember the K/S only is designed to catch detonation, not pre-ignition. And it's not to hard to change the acoustic signature so that the K/S misses some of the detonation anyway.

Needless to say, I also read my plugs fairly often, and if I saw one cylinder was constantly reading lean and another one rich, I wouldn't have a problem with swapping the two injectors to see if there was a problem.

I can only say, the 6 in my car, are leaving the plugs identically colored, as far as I can see.

Hmm, maybe batch fire has the added advantage of wetting the manifold/plenum more, and giving a better average AFR for the cylinders to draw against....

Bruce you have a lot of fireworks going off in all directions here.
Any experienced engineer will tell you that a good plan comes together not by chance but rather because of proper planning. This means having injectors which are all within +/-1% vs. +/-5%. Using one or more factory deficiencies in a system to justify adding more instability and unknowns into the mix is silly.

OE injectors have improved slightly over the years but then the Deka 4 injector is not all that new nor is the 60# orifice calibration on this injector OE spec. This is a Mototron purpose-built injector. As Joe stated, as the calibration size goes up so does the error factor. It is harder to maintain tighter tolerances on larger injectors. Even more so when building a couple thousand vs. a hundred thousand. PTE's tests just serve to back up this well known fact.

Don't get me started on Merc injectors (many made by Kei Hin Japan). I have more than a few gems here. You want some insight on Merc and HP marine applications call Livorsi Marine.

The K/S box is dinosaur technology compared to the LS1 system. I have yet to see a K/S system work properly on a TR.

Air distribution variations can be dealt with by specially ordering injectors for the individual holes (available from Racetronix), individual cylinder monitoring and injector control (aftermarket PCM DFI VII / FAST) or mechanical tuning / redirection (power plates, plenums etc.). Our import dealers are one step ahead of the domestic crowd in this respect. Many have gone to the trouble to map the cylinder to cylinder variations on a factory stock motor and figure out the % fuel trim required to get equal EGT and/or A/F per cylinder. They order injectors from Racetronix specifically suited for the application. I have discussed this in the past on some of the Buick boards and LS1TECH.com. A TR tuner has yet to approach me with this data.

Some pictures of interest might be this company who makes injector testing lines in the millions of dollars:
http://www.sonplas.com/projekte/hdev/e_index.html

or test stations for formula one racing:
http://www.sonplas.com/projekte/formel1/e_index.html

If there was nothing to be gained by flow-matching the best injectors money could buy then why would a racing team pay MEGA bucks for this setup to help their racing program?

Back to flowing injectors... we have customers to satisfy :)

Jack :cool:
Racetronix
 
Don't get me started on Merc injectors (many made by Kei Hin Japan). I have more than a few gems here. You want some insight on Merc and HP marine applications call Livorsi Marine.

Guess where a lot of the 57# Siemans injectors that Racetronix sells were used ... hint, look at some of the mid 90s Mercruiser stuff.

Again, there's nothing magic about injectors and I personally think that flowing injectors isn't a bad thing. It's always nice to have complete data about what you are doing. However, I think that some of the case here is being overstated. From looking at a QC sheet that was produced with a rig like what Jack posted above, we can see that out of a sample of 4600+ injectors the variation was within 3% for most of the sample. I'm not sure what the flap is over ...
 
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