Mercedes Mullins
Installing fuel injector bungs can be a tricky process. The bungs are welded to an intake manifold to convert to electronic fuel injection. The installation process requires careful machining of the intake to ensure a tight, leak-free seal. The angle and depth of the bungs can impact fuel delivery and airflow, so it's important to get the location right. While some people choose to install the bungs themselves, others may seek professional help to ensure proper installation and optimal performance.
How to install fuel injector bungs
| Characteristics | Values |
|---|---|
| Installation | The installation process involves welding the bung to the intake manifold. The intake must be machined to install the bung. |
| Materials | Fuel injector bungs are typically made of 6061-T6 aluminum and are welded to the manifold. |
| Dimensions | The length of the bung is typically 1.125 inches, with a 0.75-inch diameter. The inside injector dimension is 14mm. |
| Compatibility | JEGS bungs are compatible with EV1, EV6, and EV14 style injectors. |
| Purchase | Bungs can be purchased in packs of 4 or 8. |
| Guidelines | When installing the bungs, consider the angle and depth to ensure optimal fuel delivery. Aim the injector directly at the intake valve unless the application is boosted. |
| Services | Some companies offer bung installation services, including milling the manifold and welding the bungs at the correct depth. |
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What You'll Learn
Welding a fuel injector boss (or bung) to an intake manifold
Step 1: Planning
Before beginning the welding process, it is essential to have a clear understanding of the project. Decide on the type of bungs you want to use (annular or 90°) and their desired location on the runner. Consider the angles and depth of the bungs to ensure optimal fuel delivery. If you do not already have a manifold, consider the Victor manifold, which is known to work well for port EFI conversions.
Step 2: Machining the Intake
The intake must be machined to install the bung properly. This process involves drilling out the manifold runners to create the correct size and shape for the bungs. Ensure that the bungs are installed at the correct depth and that they do not protrude too much into the intake runner, as this could affect airflow. Aim the injector directly at the intake valve, unless the application is boosted.
Step 3: Welding
Once the intake is machined, it's time to weld the fuel injector boss to the intake manifold. Ensure you have a suitable welder for the job and that you are comfortable with the process. The JEGS fuel injector bungs, for example, offer plenty of materials to weld and are compatible with common injectors like EV1, EV6, and EV14. A tight, leak-free seal is crucial, so consider the machined O-ring groove to ensure a secure connection.
Step 4: Finishing
After welding, blend the bung back to the port. This step ensures a smooth finish and proper airflow. If you are unsure about performing the welding yourself, consider seeking professional help or using a bung installation service. They will have the expertise to weld the bungs at the correct depth and ensure a secure connection.
Welding a fuel injector boss to an intake manifold requires careful planning, machining, and welding. It is important to consider the type of bungs, their location, and the welding process to ensure a secure and functional connection. With the right tools, knowledge, and guidance, you can successfully install fuel injector bungs to enhance your engine's performance.
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Drilling out a manifold runner to install the bung
Drilling out a manifold runner to install a bung is a complex process, and it is important to get it right to ensure optimal fuel delivery. The first step is to decide on the type of bung you want to use – annular or 90-degree – and where on the runner it will be placed. This will determine the angle and depth of your drilling.
The drilling itself can be tricky, and it is important to use the right tools. One person shared their experience of using a 1/2" hand drill while standing on a chair and holding the manifold in a bench vise. They noted that when the bung hole got larger (over 1/2"), the drill bit started grabbing and trying to tear the manifold material. In this case, they transitioned to a die grinder to complete the drilling process.
Another important consideration is the placement of the injector/bung unit in relation to the intake runner. You want to avoid setting it too far into the intake stream as this could affect airflow into the combustion chamber.
If you don't feel comfortable drilling and welding your own manifold, you can send it to a company that offers bung installation services. They will mill your manifold, weld in the bungs at the correct depth, and blend it back to the port. This ensures that the bungs are installed properly and that your manifold is in good hands.
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Choosing the right bung for your nozzle
When choosing the right bung for your nozzle, there are several factors to consider. Firstly, it is important to determine the specific requirements of your engine and application. This includes considering factors such as idle quality, emissions, fuel mileage, and engine-compartment packaging constraints. For example, on a stocker, fuel injector capacity is typically lower compared to a race engine, and inlet-runner velocity and low-speed vacuum are higher. Understanding these factors will help you select a bung that is compatible with your engine's needs.
Another important consideration is the injector angle and location. The ideal nozzle location should be as parallel to the airflow stream as possible, with an intercept angle of no more than 45 degrees. This intercept angle plays a crucial role in low-speed driveability and can also impact performance throughout the engine's operating band. Therefore, when choosing a bung, ensure that it allows you to maintain the proper injector angle and location to optimize engine performance.
The type of connector used by the injector is also a key factor in choosing the right bung. There are two common connector styles: the older Jetronic/Minitimer style connector and the newer USCAR connector. The Jetronic/Minitimer style uses a rectangular housing with two flat connector prongs, while the USCAR connector is square and employs narrower, rounded prongs. Additionally, it's worth noting that some injector body styles, such as EV1, EV6, and EV14, may indicate the type of connector used, and certain connectors could be OEM-specific.
Finally, consider the size and compatibility of the bung with your nozzle. Fuel injector bungs come in various sizes, such as 0.75 inches by 1.75 inches or 1.125 inches long with a 0.551-inch inside diameter. Ensure that the bung you choose fits securely and properly with your nozzle to avoid any leaks or performance issues. It is also recommended to refer to product reviews and ratings to gain insights from the experiences of other customers who have used similar products. By taking these factors into account, you can make an informed decision when choosing the right bung for your fuel injector nozzle.
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Ensuring a tight seal with a machined O-ring groove
Next, calculate the O-ring groove diameter based on the type of seal. For a rod (shaft) seal, the formula is O-Ring Max Groove Diameter = Min Shaft Diameter + (2 x Recommended Gland Depth). For a bore (piston) seal, the formula is O-Ring Min Groove Diameter = Max Bore Diameter – (2 x Recommended Gland Depth). And for a face seal, the O-Ring Max Groove Depth = Recommended Gland Depth – Application Clearance. Refer to product tables to determine the groove width for the O-ring cross-section size. If a back-up ring is used, increase the groove width accordingly.
Additionally, consider the percent gland fill, which should not exceed 100%. Use Equation 6 to determine the maximum percent gland fill. Calculate the minimum and maximum seal cross-sectional compression (squeeze) using Equations 3 and 4. For applications involving high pressure or large component tolerances, verify the seal and groove design through testing or engineering analysis. Select the proper O-ring size from the Standard Size table, ensuring it matches the bore or rod (shaft) size.
Finally, consider the groove design itself. Dovetail grooves, for example, are effective at holding the O-ring in place during assembly and maintenance, but they are expensive to machine and should only be used when necessary. A flange or face seal is static, eliminating any issues associated with extrusion. A dynamic gland seal, on the other hand, is used when mating components are moving relative to each other, resulting in a gap between the surfaces. Backup rings are crucial in high-pressure sealing applications to eliminate the extrusion gap.
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Converting to electronic fuel injection
The first step is to assess your engine setup and requirements. You will need to decide on the type of bung, such as annular or 90-degree, and the number of bungs required. The intake manifold will need to be modified to accommodate the bungs, and this can be done by drilling or machining. It is important to note that the injector bungs should not protrude too far into the intake runner, as this could affect airflow and engine performance.
When installing the bungs, it is crucial to ensure they are positioned correctly and securely. The bungs are typically welded onto the intake manifold, and this process requires precision and a good understanding of welding techniques. The depth and angle of the bungs are important factors to consider, as improper installation can lead to fuel delivery issues and performance problems. It is recommended to seek professional help or advice if you are unsure about the process or don't have the necessary equipment, like a welder.
The type of fuel injector and manifold you use will also impact the installation process. Some injectors, such as the EV1, EV6, and EV14 styles, are commonly used and have compatible bungs available. Additionally, certain manifolds, like the Victor, are known to work well for port EFI conversions, especially with larger engines. It is always a good idea to research and plan your specific setup before beginning the installation process.
Finally, it is important to consider the overall setup and any potential issues. For example, aiming the injector directly at the intake valve is ideal, but this may not be possible with all engines. Additionally, the ECM (Engine Control Module) can play a role in fuel delivery and should be considered, especially if you have a sophisticated system. Converting to EFI is a complex process, and it is always recommended to seek advice and guidance from experienced professionals or mechanics.
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Frequently asked questions
Fuel injector bungs are used to convert to electronic fuel injection. They are welded onto an intake manifold.
The intake must be machined in order to install a fuel injector bung. You can either do this yourself or send your manifold to a company that offers a bung installation service.
Fuel injector bungs are typically made from 6061-T6 aluminium.
There are two types of fuel injector bungs: annular and 90°.
The type of bung you choose will depend on the type of manifold you have. It's important to consider the angles and depth of the installation to ensure optimal fuel delivery.
