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Tuning notes for Bosch 1600cc injectors (Ford, Chrysler)

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the_mork

15+ Year Contributor
2,619
25
Mar 10, 2008
Eau Claire, Wisconsin
I expect for the most part that these are the final settings for e85

Right side of the latency table
3.312
2.904
2.304
1.464
0.96
0.696
0.144

Scaling = 886 or 914 depending on which station I get my e85 from.

These injectors now have perfect manners for me including single crank starting which I never had with stock or evo injectors. What strikes me as different and is probably the reason that many people have problems with these injectors is that you cannot rely on only the correct deadtimes and scaling to make the car idle and cruise nicely. In order to get past the ugly part of their flow chart and keep your pulsewidths wide enough to avoid pintle bounce which will make 1.2-1.7ms pulsewidths richer than 2.0ms pulsewidths you'll need to adjust either SD settings (mapVE and rpmVE) or the MAF comp table to help control 0-60 load under 1250 RPM. Expect that you'll need to increase your asynch vs TPS delta as well by a substantial amount for throttle transients to not go lean and hesitate. I also modified a 1g fpr to fit a 2g rail. The lower pressure regulator was not necessary for e85 but since I had already bought the fpr before I had the injectors acting nicely I decided to put it on anyway in hopes that it will make pump gas tuning nicer if I ever am forced to do that. Until I am for some reason forced into running pump gas I'm not likely to update this thread with any pump gas experience beyond what I've already described which should not be taken to mean anything. I was using very much the wrong deadtimes and taking wild stabs at all other tuning aspects with the last gallon of gas in the tank IMO for cars that live in areas where e85 is plentiful these injectors are an awesome budget choice. I'm looking forward to reading about anyone else's experiences with these especially on gasoline.

Original post ----------------------------------------------------------------

the_mork said:
I picked up a set of injectors for a great price so I'm going to see how well I can tune them. Despite a fair amount of knowledge about the evo8 ecu I'm using this is the first set of injectors that I have to actually scale myself. There is very little information about these injectors as far as what works and what doesn't and much of the available information is contradictory. What I do know is that the are huge and are further problematic because they flow more at 1.2ms pulsewidth than 2.0ms. Ugly to say the least. This thread is primarily to share my experience and get some feedback from anyone else attempting to go through the same process.

Information from Injector Rehab
Injector-Rehab - Fuel injector cleaning, flow testing, and complete blueprinting service.

Ford Motorsport
1600

152

5


1.61 10v

1.32 11v

1.11 12v

0.96 13v

0.83 14v

0.72 15v


Found these on evolutionm.net supposedly the same injectors
6v-17v

2.31 2.06 1.84 1.70 1.59 1.47 1.38 1.29 1.20 1.05 .95 .64


Neither set of deadtimes works.My current deadtimes (attachment) are not correct but are inbetween these. These are rough and definitely don't make the car happy but the car does idle. Currently on gas I'm idling around 12:1 with a scaling of 1329.

E85 scaling is 943 and usually idles around 14.6:1 with a fuel map calling for 15.3:1.

General observations are that these injectors suck on straight gasoline. I spent about 25 minutes trying to dial them in enough to get to the gas station and finally got to where I could drive the car there but it was not a fun ride. Quick scaling on e85 netted driveability (though still pretty bad) in about 5 minutes. After that I drove the car home and put it to bed for the night.

Progress will be slow because this is exam time for me but I'll update as things go. I expect good driveability on e85 when I'm done and acceptable manners on pump when I absolutely need it. FWIW stepping on it is pretty near perfect but I haven't touched timing for the e85 switch yet.
 

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Hey. Those were my deadtimes i got from Deatsch Werks. Supposedly from what i read, its pretty much impossible to get these to idle and run correctly on gas because they are so large and cannot be compensated without the help from an additional injector driver helping.

I will also be running strictly E85 on my 1600's and hopefully will be able to dial them in. How is your fuel trims and what not on that latency and scaling on e85? And are your running a stock map adjusted for e85 or what? Could you send me your map to check out? Thanks.

I would like to work together to see if we can get these things working well enough to drive and boost on safely!

James
 
Those problems you had on gasoline are pretty typical for a 1600. For me, this graph really drove home why. Log your IPW at idle, and it'll be pretty obvious what's happening. (I don't have a helpful suggestion, unfortunately, other than to raise your idle RPM to higher than the trouble point, or run a fuel that requires more IPW at idle. ;))
 
I've seen that graph before and I'm going to image link it in this thread so that others see exactly what is going on right away.
You must be logged in to view this image or video.


My ipws were 1.5-1.7 on gas and I'm not sure what they were on e85. I'm not trying to idle well on gas, just get down the road when I have to fill up on a road trip or something. Cruise needs to be fine though.

Vette, that is because they are the same injectors. As far as I can tell Deatsch injectors are just rebranded Bosch injectors. If you look on the injector rehab link I posted there is also a listing for Bosch injectors which are incredibly close in flow and deadtime to the Ford ones, I'm not sure which deadtimes to use but I also don't think it matters because in seeing how close the dead times are I assume they are basically the same injector.
 
So if we can get our injectors to above the 2 msec pulse width, which should be attainable on e85, then we should be able to get the latencies and scaling dialed in for the injectors correct?
 
It is supposed to still be fairly interesting but I'm hoping to get there. I suspect we actually need to pass 2.2ms or so to be consistent throughout all conditions but that may be unrealistic. I'll keep working on it but like I said I don't have a lot of time.
 
Well, i should be getting my car on the road here very shortly so ill be trying to figure it out as well. I just need to finish my evo brake setup and then ill be working on it. Can evoscan log the ipw?
 
Haha. Im sure e85 will make things much easier. Thats all i plan on using on this car. Thats why i got such big injectors.
 
I will also be running strictly E85 on my 1600's and hopefully will be able to dial them in. How is your fuel trims and what not on that latency and scaling on e85? And are your running a stock map adjusted for e85 or what? Could you send me your map to check out? Thanks.

I skipped over this question earlier but not on purpose. My fuel trims don't mean anything because I run strictly open loop. I may try playing with closed loop a bit but I doubt it will net better driveability on pump gas and hopefully I can get these right on e85 without closed loop. As for my maps, they are just gas maps right now and nothing special. 15.3:1 anywhere that is 14.7:1 in a stock map and 11.0:1 anywhere that was below 11:1 previously. My map isn't right for e85 or gas, it is just a map to make it obvious what needs to be tuned to get AFRs in the right place with plenty of space to go lean before hurting anything. Once I have my injectors dialed in I'll start shooting for 12.0 WOT AFRs and messing with my timing map.

The only thing that I can say about timing so far is that these injectors don't like lots of idle timing on pump gas, I had my idle timing as 7s but moved them back down to stock 5s for sanity.
 
I skipped over this question earlier but not on purpose. My fuel trims don't mean anything because I run strictly open loop. I may try playing with closed loop a bit but I doubt it will net better driveability on pump gas and hopefully I can get these right on e85 without closed loop. As for my maps, they are just gas maps right now and nothing special. 15.3:1 anywhere that is 14.7:1 in a stock map and 11.0:1 anywhere that was below 11:1 previously. My map isn't right for e85 or gas, it is just a map to make it obvious what needs to be tuned to get AFRs in the right place with plenty of space to go lean before hurting anything. Once I have my injectors dialed in I'll start shooting for 12.0 WOT AFRs and messing with my timing map.

The only thing that I can say about timing so far is that these injectors don't like lots of idle timing on pump gas, I had my idle timing as 7s but moved them back down to stock 5s for sanity.

Ah. I am going to run closed loop to dial in my fuel trims first. Do you buy chance have the new scaling for the dsm maf sensor for the new rom 0715? I know your on SD, which im not sure how your able to run SD without fixing your injectors first for your VE. OR are those already correct from your previous tune? Any help for me in that since im also trying to convert to SD?
 
I made sure my SD tune was right before switching injectors. I doubt you'll be able to use closed loop for anything useful with these injectors. The ecus compensation simply isn't going to do anything positive for you.

I have never followed any efforts to deal with the 2g MAF on an evo8 ecu if that is what you're asking.

Converting to SD is easy, kill closed loop and set your fuel map to where you want it but pull half a point of fuel everywhere that being lean might be dangerous. If you have VE maps to follow then start with them but I didn't so I just winged it. Do a pull and use maptracer to see where your AFRs are, if they are lean/rich universally down a load column then change the MAP sensor VE, if they are universally lean/rich then change the RPM VE. Continue until you get it right.

Back to the topic.

I did about 15 minutes of driving today and 10 minutes playing around with the idle. 75% of the time I can maintain a decent idle at a decent AFR, the other 25% of the time I'm either pegging lean or rich around 12:1. Cruise and WOT are pretty decent with an e85 scaling near 1000.
 
I made sure my SD tune was right before switching injectors. I doubt you'll be able to use closed loop for anything useful with these injectors. The ecus compensation simply isn't going to do anything positive for you.

I have never followed any efforts to deal with the 2g MAF on an evo8 ecu if that is what you're asking.

Converting to SD is easy, kill closed loop and set your fuel map to where you want it but pull half a point of fuel everywhere that being lean might be dangerous. If you have VE maps to follow then start with them but I didn't so I just winged it. Do a pull and use maptracer to see where your AFRs are, if they are lean/rich universally down a load column then change the MAP sensor VE, if they are universally lean/rich then change the RPM VE. Continue until you get it right.

Back to the topic.

I did about 15 minutes of driving today and 10 minutes playing around with the idle. 75% of the time I can maintain a decent idle at a decent AFR, the other 25% of the time I'm either pegging lean or rich around 12:1. Cruise and WOT are pretty decent with an e85 scaling near 1000.

Well, the only thing i can say is ill try to go open loop with my maf and try to get a good sclaing number for us since your not going to be able to in closed loop. Ill dial the mid trims as close to 1 as possible.

Did you happen to log your IPW?
 
Yes, I log IPW all the time. I'm consistently in the 1.5ms-2.0ms range at idle which is the ugly spot for these injectors. I'm likely going to start by putting a 1g manual FPR on my car to drop fuel pressure. If that doesn't work I'll go to an aftermarket regulator and drop pressure even more. I'm only using an evo9 fuel pump so there is no way that I'm going to be making real use of these injectors until I upgrade my pump and FPR.
 
So that a wider injector pulse width provides less fuel so that idle tuning is easier. My car just doesn't require 6.5L of fuel per minute with my 16g, and I don't know many cars that do. 38psi fuel pressure will make these act like 1400cc injectors on gas and 1000cc injectors on e85 which will still be plenty of fuel for me and hopefully get me back to that 1.9-2.1ms pulse width that I want.
 
Hmm. Gotcha. What kind of adjustments to your tune are required then to run a lower BFP? There isnt a place to change the BFP in the ecu is there?
 
AH. Thats right! Ok. Well i guess ill still try to get mine working with my setup and see if i have any sucess with open loop and and at stock bfp
 
Got the car idling and driving acceptably last night with only a little hesitation on throttle transients which I hope I can clear up by changing the asynch accel tables.

Idle surge while cruising at 25mph is a bi*** though.

I've heard of people changing the resistors in the resistor pack to make higher (but not high) impedence injectors work better, anyone have information on how badly I might damage my ecu if I drop a couple of ohms? I would hate to burn out my injector drivers but these 5 ohm injectors could probably run better with less resistance before them.
 
Got the car idling and driving acceptably last night with only a little hesitation on throttle transients which I hope I can clear up by changing the asynch accel tables.

Idle surge while cruising at 25mph is a bi*** though.

I've heard of people changing the resistors in the resistor pack to make higher (but not high) impedence injectors work better, anyone have information on how badly I might damage my ecu if I drop a couple of ohms? I would hate to burn out my injector drivers but these 5 ohm injectors could probably run better with less resistance before them.

How was 60 mph cruising?
 
No idea, I'll get there when I get to a highway but right now I'm basically only driving to school and back which is a little over a mile.

Driving is now great with nice transients and great manners. low speed cruise surge is gone but idle surge is still a problem. I suspect the ISC is fighting the injectors and this is more of a problem with me not knowing enough about idle air tuning rather than a problem with my injector latencies/scaling. Still richer than I'd like but getting pretty close. I would post settings but I'm incredibly busy today, update late tonight or tomorrow.
 
No idea, I'll get there when I get to a highway but right now I'm basically only driving to school and back which is a little over a mile.

Driving is now great with nice transients and great manners. low speed cruise surge is gone but idle surge is still a problem. I suspect the ISC is fighting the injectors and this is more of a problem with me not knowing enough about idle air tuning rather than a problem with my injector latencies/scaling. Still richer than I'd like but getting pretty close. I would post settings but I'm incredibly busy today, update late tonight or tomorrow.

Yes please post them. All your settings if possible.
 
Just posting the rom for the moment, capturing all the changes would be hard and take a lot of explanation. Pay attention to the asynch fuel table as well as the idle tables. Smoothing idle is the important part here but also I'm using the SD tables like fuel control in the low end. To recreate results like that you'll have to use the MAF smoothing tables. If you do some research and figure out how to fix the idle surge (almost certainly caused by my mucking about with the desired idle tables without touching the ISC position tables) then let me know.

If the definitions file (xml) doesn't show up in this post you can find it recently in the evo8 ecu thread.
 

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  • base-bosch-e85=r2-open.hex
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