928 batch to sequential injection conversion, electronics wizards needed
#31
Rennlist Member
I am trying to accomplish a few things.
Mainly there is a resonance in the fuel rails on our cars. I have seen it on my car and others. It appears on both NA and supercharged cars. It seems like the larger the injector, the more obvious the affect is. I am not sure if the dead ended fuel rails make it worse or not, but it surely doesn't help.
it would also lessen the clicking noise heard from the injectors, and the need for dampers.
Mainly there is a resonance in the fuel rails on our cars. I have seen it on my car and others. It appears on both NA and supercharged cars. It seems like the larger the injector, the more obvious the affect is. I am not sure if the dead ended fuel rails make it worse or not, but it surely doesn't help.
it would also lessen the clicking noise heard from the injectors, and the need for dampers.
I believe the dampers are sized for the amount of fuel needed at idle and cruise, where injector pulse-widths are in the 1.5-2ms range (net of latency, 2.5-3ms total pulse width). So in theory larger injectors don't matter-- 40# injectors are .75-1 ms instead of 1.5-2, but the fuel quantity doesn't change. So stock dampers should be fine, IF they are left in place.
Batch-fire has no problem idling. This was underscored by an interesting experiment we did recently, as part of a project to look at injector latency. Normally the LH fires once per revolution. If that's an issue, then changing that to once per two revolutions would make it worse, correct? No change. I'll repeat that: No change in how the car idled. If idle is compromised by batch firing, then batch firing at half the rate would have to be worse. (Changing to once per three revolutions did start to make the idle lumpier).
One driver, fires all eight together and normally once per revolution.
#33
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#34
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I am all in for something like this. I'd love to ditch the LH and EZK and move to coil packs. Seems like it would be a fun project.
#35
Rennlist Member
Not that I know of.
Murf928, 928 Motorsports, ptuomov's turbo, 928 Specialists, Greg Brown's strokers (the ones with the original ECU) etc.... do not suffer from any fuel line resonance that I've ever heard about.
I can only speak in greater detail about the Murf928 setup since I'm a bit familiar with it's design.
The Murf928 Supercharger system was designed from the start to retain as many stock parts as possible. This makes everyday use (like idling, cruising around in traffic) much easier to tune for.
The Murf928 tune has very few modifications to the fuel and ignition map off boost. It simply wasn't needed.
DR's setup from 928 Specialists also uses 100% stock fueling (dampeners, rails, FPR's etc...) With zero resonance issues with 42# injectors.
Reading all the posts trying to tune Victor's setup on and off boost really had me scratching my head until I learned how flawed the fuel system is.
This fuel resonance is a problem unique to a setup that removed dampeners under the assumption they were "not needed". I'm sure a lot of testing went into determining that......
As for the dead-ended fuel rail, I have been speechless on ever since I learned about it. I simply cannot believe such a setup was brought to market and sold to customers.
Not only is the dead-ended fuel rail a major mistake, having the #5 injector so close to this "dead end" pretty much guarantees the fuel flow to that one injector will be different form the rest.
Trying to go batch fire just to fix an obvious design flaw such as this, is like using a tourniquet to stop a nose bleed.
Murf928, 928 Motorsports, ptuomov's turbo, 928 Specialists, Greg Brown's strokers (the ones with the original ECU) etc.... do not suffer from any fuel line resonance that I've ever heard about.
I can only speak in greater detail about the Murf928 setup since I'm a bit familiar with it's design.
The Murf928 Supercharger system was designed from the start to retain as many stock parts as possible. This makes everyday use (like idling, cruising around in traffic) much easier to tune for.
The Murf928 tune has very few modifications to the fuel and ignition map off boost. It simply wasn't needed.
DR's setup from 928 Specialists also uses 100% stock fueling (dampeners, rails, FPR's etc...) With zero resonance issues with 42# injectors.
Reading all the posts trying to tune Victor's setup on and off boost really had me scratching my head until I learned how flawed the fuel system is.
This fuel resonance is a problem unique to a setup that removed dampeners under the assumption they were "not needed". I'm sure a lot of testing went into determining that......
As for the dead-ended fuel rail, I have been speechless on ever since I learned about it. I simply cannot believe such a setup was brought to market and sold to customers.
Not only is the dead-ended fuel rail a major mistake, having the #5 injector so close to this "dead end" pretty much guarantees the fuel flow to that one injector will be different form the rest.
Trying to go batch fire just to fix an obvious design flaw such as this, is like using a tourniquet to stop a nose bleed.
My car with the Victor kit is now running great. Lots of power, idles very nicely and tuning is right on. I am still interested in this injection idea I am a newbie to tuning compared to you guys but anything that can give us more mileage and more power with more tuning options and we can move to modern electronics running the engine would be cool.
Seems like we could then integrate this into a touchpanel controller for HVAC, audio, nav . . . oh wait that was discussed before and that project withered and died.
#36
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let me follow up on a few things...
The front initial damper is still used in the system, it is just moved to the back.
I have seen this resonance on a few of different plots from other cars not with my kit. The one that first comes to mind was from Tonys twin screw car.
We have no issue with the 36# injectors and dead ended fuel rail that come in the kits. The cars run great. But when people are using large injectors like 60#, there is an obvious resonance. I was looking for a solution to that resonance on the large injectors for when people want to go big with lots of boost. I was thinking after looking at the schematics that this might be a solution. I still think it can be done, but apparently not so easily. The more obvious choice for people that want to go big, is to change over to an aftermarket engine management setup that will allow not only sequential, but also COP and MAP, so that the MAF can be pitched. If there is such a system that is in the works with prefab cabling and programming, then that would make life easy and I will be watching for it.
I have been looking at reworking the drivers side fuel rail and returning to a flow through design with a front damper relocation. I definitely want to continue using the stock fuel rails, and it needs to be a simple solution. There is just not a lot of room available.
The front initial damper is still used in the system, it is just moved to the back.
I have seen this resonance on a few of different plots from other cars not with my kit. The one that first comes to mind was from Tonys twin screw car.
We have no issue with the 36# injectors and dead ended fuel rail that come in the kits. The cars run great. But when people are using large injectors like 60#, there is an obvious resonance. I was looking for a solution to that resonance on the large injectors for when people want to go big with lots of boost. I was thinking after looking at the schematics that this might be a solution. I still think it can be done, but apparently not so easily. The more obvious choice for people that want to go big, is to change over to an aftermarket engine management setup that will allow not only sequential, but also COP and MAP, so that the MAF can be pitched. If there is such a system that is in the works with prefab cabling and programming, then that would make life easy and I will be watching for it.
I have been looking at reworking the drivers side fuel rail and returning to a flow through design with a front damper relocation. I definitely want to continue using the stock fuel rails, and it needs to be a simple solution. There is just not a lot of room available.
#37
Rennlist Member
The IMR was added to protect against fires caused by failure of one ignition bank, by cutting 12v power to one injector bank. The LH is still trying to fire all eight on the ground side. Ignition issues are generally wires or coils, the EZK and drivers are pretty bullet-proof.
#38
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Hacker ... I know you are a Murf fan and I have no issue with that. As I have no issue with the Murf system and have recommended it to few people that have the OB cars. The purpose of a forum is to make forward progress and share knowledge. As a moderator I would think bashing would be frowned against, especially when the host company is trying to sign me up for advertising and the like.
#39
Rennlist Member
I cannot speak for every ST2 user but I can see clearly on my sharkplotter that there are resonance zones with the stock system. As Jim says, the amount of fuel has not changed with bigger injectors but the pulse width drops. The resonance does not occur at top rpm's but something around 2k or so I seem to remember. I do not know if it is a first order harmonic or just the first event we see. 19lb injectors are exhausted at around 400 crank bhp so bigger injectors are clearly justified but 60lb ones? 32lb injectors can crank out around 600 bhp so logic suggests they should be more than adequate.
The problem with bigger injectors is that they are quite possibly going to be timed to such small intervals that at lower rpms and low load values the flow is going to be more choppy and less accurate/reliable metering as a consequence.
As you are modifying the 5/8 fuel rail -presumably shortening it and thus dead heading injector No5 completely, is it not possible to simply modify it such that you have a through flow design retained via side entry or whatever spacial geometry permits? Porsche did not put dampers there because they liked the look of them so they obviously knew something was going on. At low fuel flow rates perhaps the fuel is heating up locally in the rail and leading to other issues?
I cannot say I am surprised that this phenomena is seemingly being amplified. That you have come up with the kit you have tells me you are smart enough to solve this one.
There is nothing wrong with attempting sequential injection- however tuning the batch fired system is enough of a headache for me.
Regards
Fred
#40
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I can't see any plusses in having a car that doesn't run right, and spending north of $3k to get there, compared to spending only $1200 for a new factory harness and having a car that just runs right.
Victor, I'd have thought that non-destructive is the only sensible approach, so a car can be returned to stock easily, which means completely supplanting the injection harness (which includes all the intake sensor connectors) to support sequential injection.
If thats the case it seems that fixing the fuel rail and dampener setup would be inherently cheaper for a customer to do than a complete new standalone ECU setup.
Do any of the other boost kits suffer from this resonance? I haven't seen any posts about it with respect to the Murf kit which uses stock ECU's (with custom EPROMs) and 42lb injectors.
Victor, I'd have thought that non-destructive is the only sensible approach, so a car can be returned to stock easily, which means completely supplanting the injection harness (which includes all the intake sensor connectors) to support sequential injection.
If thats the case it seems that fixing the fuel rail and dampener setup would be inherently cheaper for a customer to do than a complete new standalone ECU setup.
Do any of the other boost kits suffer from this resonance? I haven't seen any posts about it with respect to the Murf kit which uses stock ECU's (with custom EPROMs) and 42lb injectors.
Wouldn't know what it is or what it feels like in my car. Ive got 42#s and boost...runs great. Mixture and drivability are fine. Im all for advancing the technology on the car but if you can get 500hp out of the stock system with the aid of a sharktuner what else more do you need?
What power gains will coil on plug get you? sequential injection? all of it combined?. Personally, I find the gains trivial to the amount of money and time spent to set it up. Now that I have upped my power with boost first, I wouldn't mind adding the finer elements of this type of tuning though..
each his own
#41
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Victor,
I cannot speak for every ST2 user but I can see clearly on my sharkplotter that there are resonance zones with the stock system. As Jim says, the amount of fuel has not changed with bigger injectors but the pulse width drops. The resonance does not occur at top rpm's but something around 2k or so I seem to remember. I do not know if it is a first order harmonic or just the first event we see. 19lb injectors are exhausted at around 400 crank bhp so bigger injectors are clearly justified but 60lb ones? 32lb injectors can crank out around 600 bhp so logic suggests they should be more than adequate.
The problem with bigger injectors is that they are quite possibly going to be timed to such small intervals that at lower rpms and low load values the flow is going to be more choppy and less accurate/reliable metering as a consequence.
As you are modifying the 5/8 fuel rail -presumably shortening it and thus dead heading injector No5 completely, is it not possible to simply modify it such that you have a through flow design retained via side entry or whatever spacial geometry permits? Porsche did not put dampers there because they liked the look of them so they obviously knew something was going on. At low fuel flow rates perhaps the fuel is heating up locally in the rail and leading to other issues?
I cannot say I am surprised that this phenomena is seemingly being amplified. That you have come up with the kit you have tells me you are smart enough to solve this one.
There is nothing wrong with attempting sequential injection- however tuning the batch fired system is enough of a headache for me.
Regards
Fred
I cannot speak for every ST2 user but I can see clearly on my sharkplotter that there are resonance zones with the stock system. As Jim says, the amount of fuel has not changed with bigger injectors but the pulse width drops. The resonance does not occur at top rpm's but something around 2k or so I seem to remember. I do not know if it is a first order harmonic or just the first event we see. 19lb injectors are exhausted at around 400 crank bhp so bigger injectors are clearly justified but 60lb ones? 32lb injectors can crank out around 600 bhp so logic suggests they should be more than adequate.
The problem with bigger injectors is that they are quite possibly going to be timed to such small intervals that at lower rpms and low load values the flow is going to be more choppy and less accurate/reliable metering as a consequence.
As you are modifying the 5/8 fuel rail -presumably shortening it and thus dead heading injector No5 completely, is it not possible to simply modify it such that you have a through flow design retained via side entry or whatever spacial geometry permits? Porsche did not put dampers there because they liked the look of them so they obviously knew something was going on. At low fuel flow rates perhaps the fuel is heating up locally in the rail and leading to other issues?
I cannot say I am surprised that this phenomena is seemingly being amplified. That you have come up with the kit you have tells me you are smart enough to solve this one.
There is nothing wrong with attempting sequential injection- however tuning the batch fired system is enough of a headache for me.
Regards
Fred
#42
Rennlist Member
Been reading this topic with great interest, and thought I would share my experience with sequential injection and direct fire coils, that I had installed and tuned on my '86.5 a few years ago. Before installation of the Tec3r my car dynotested at around 250 at the wheels, compression was between 169 and 171 on the cylinder (most at 170). After installing the Tec3r AND tuned on the dyno, the car produced 279 rwhp on the same dyno with zero knock events. Fuel economy was improved noticeably, went from 20-22 to roughly 24-25 mpg highway consistently over a few years. The engine felt livelier and seemed to love the upper RPM range more than before.
Could the stock system have been tuned to the same level? Possibly. There was no Shartuner available back then, and it was my personal preference to have a modern 32-bit computer and new wiring instead of a 25-year old system that was getting more and more touchy and fragile as the years went by. The manufacturer claimed a 7% increase in fuel economy over stock....I got fairly close to that, with an increase in power at the same time. BUT, it took a lot of tuning, both dyno and road driving with a helper in the right seat making adjustments while I was driving.
Would I do it again? Definitely. Again, this is my personal experience, and I thought I would share it.
If one looks at the modern aftermarket options, there are now MSD, FAST and Holley computers with self-learn/self-tune capability far superior to the self-tuning I had available back then.
Cheers!
Carl
Could the stock system have been tuned to the same level? Possibly. There was no Shartuner available back then, and it was my personal preference to have a modern 32-bit computer and new wiring instead of a 25-year old system that was getting more and more touchy and fragile as the years went by. The manufacturer claimed a 7% increase in fuel economy over stock....I got fairly close to that, with an increase in power at the same time. BUT, it took a lot of tuning, both dyno and road driving with a helper in the right seat making adjustments while I was driving.
Would I do it again? Definitely. Again, this is my personal experience, and I thought I would share it.
If one looks at the modern aftermarket options, there are now MSD, FAST and Holley computers with self-learn/self-tune capability far superior to the self-tuning I had available back then.
Cheers!
Carl
#43
Nordschleife Master
Main advantage I see with sequential is that its possible to calibrate the flow on each injector by one at a time adjusting pulse width up and down rich/lean and watching the O2 sensor. At higher power levels sequential isn't any different from bank fired, both will be open most of the cycle.
#44
Nordschleife Master
Definitely - 85/86 stock tune is now well known to be woeful. A search for porken's threads and chips will shed more light.
#45
Nordschleife Master
I got 320rwhp, and 330rw ft lbs on an 86.5 motor after more tuning. (stock manifolds, H pipe, 2.25")
Prior to the final tune I put down 310/320 rwhp on Louie Ott's Dyno in 2007.....
I tuned aggressively for fuel economy, and saw 30+MPG on the freeway while maintaining the same power.
The high power ignition systems do gain fuel efficiency, as well as power. However the amount of time one can spend tuning the car is unreal. The same can be said for the sharktuner though......
This is why I do a nice curve in the map tailing up and down, doing runs to confirm my AFR, the runs are at different MAP values, and I trim the entire curve up/down. This gives a very consistent AFR, and I tune the ignition relatively conservatively on most engines. The benefit to this is that if something happens and the car goes to a different part of the map, the car will respond identically.
Case in point a local 82 I boosted, he said as he would get into the boost the car would just shut off then come down and reengage. I checked and sure enough the line to the wastegate had broken.
The boost safety shut off (MSII V3.57) was set at 19 PSI. Though I had only technically tuned to 17, the car showed no problems after him driving it like this for two weeks before I found out about it......
Prior to the final tune I put down 310/320 rwhp on Louie Ott's Dyno in 2007.....
I tuned aggressively for fuel economy, and saw 30+MPG on the freeway while maintaining the same power.
The high power ignition systems do gain fuel efficiency, as well as power. However the amount of time one can spend tuning the car is unreal. The same can be said for the sharktuner though......
This is why I do a nice curve in the map tailing up and down, doing runs to confirm my AFR, the runs are at different MAP values, and I trim the entire curve up/down. This gives a very consistent AFR, and I tune the ignition relatively conservatively on most engines. The benefit to this is that if something happens and the car goes to a different part of the map, the car will respond identically.
Case in point a local 82 I boosted, he said as he would get into the boost the car would just shut off then come down and reengage. I checked and sure enough the line to the wastegate had broken.
The boost safety shut off (MSII V3.57) was set at 19 PSI. Though I had only technically tuned to 17, the car showed no problems after him driving it like this for two weeks before I found out about it......