Large Port Manifold Injector Seats

[YerMother]

I got hold of a large port inlet manifold and trying to fit it to my BAM engine and the injector seats are too small for the injector to slot in. The injector diameter is the same(nozzle with the 'o' rings) but the injector body itself is too wide for the injector to slot all the way in. You can't simply swap the seats over either as the overall diameter of seat that screws into the manifold is wider!

Any one know of any way to overcoming this?

 

[YerMother]

Is there different OEM seats that will screw into the mani but take the larger injectors?

 

[Wilko]

The seats are a couple of quid from the dealers. You can fit small port seats to a large port manifold.

 

[YerMother]

The injector seats on my small port mani are around 32mm in diameter and the one in the large port mani are are 27mm. The allen size to remove the small port seats is around 20mm and the largeport is around 18mm.

Are you saying you can get 27 diameter seats with 20mm hex? Or am i going to have to machine the large port mani to get the small port seats to fit?

 

[YerMother]

Sorted now. I had to "modify" the large port injector seats slightly to fit the wider injectors.

The VW Sharan manifold (Large port pre 2000) is now on my LCR, it's by no means a straight swap! The charge pipe bracket above the auxiliry belt tensioner needs to be spaced out by around 5mm, the throttle body turbo hose needs to be extended slightly, the manifold itself needs to be ground down to allow the fuel rail to fit and then finally all your vacumn hoses need to be re-routed.

I haven't been for a good run yet, but when the weather gets a bit better I'll do some logging for comparison. Initial impressions are good very good but that could be just the subzero temperatures.

Looks good though!

 

[wild willy]

Nice one Simon, your one of the few on here who is prepared to take the initial plunge on new ideas etc and have given me the confidence to copy which i have always reaped good rewards from. I hope you get good gains from it, surely a big ass intake mani is to follow.

 

[YerMother]

I thought it was worth doing. As while i had the head off I ported the inlets to match the large port gasket I got hold of. Which is around 5mm wider either side than the small port!!

This is my project complete now.

I would defo get the forge actuator, drives alot smoother now and boost control is alot better now the wastegate can fully open. Just be sure to get a slightly longer actuator rod (around 10mm) and be prepared th alter the mounting bracket as it doesn't fit properly. I think that this was because our hybrid has a different back plate to the compressor housing due to the larger compressor. I'm using the yellow spring which is said to be 9-15psi

I may right an overall review if i can be bothered after some logs and dyno plots have been done.

 

[Feel]

I should've said - I remembered that the Sharan inlet wouldn't fint with the stock charge pipe, 'cos Ryan contacted me about a "speshul" custom charge pipe.

Anyway, you got it on.

Got to be a good way to go on your motor - no real need for a "full" inlet manifold. Shame we never found anyone that would do extrude honing

 

[YerMother]

I can make anything fit!

What do you mean by your final paragraph mate? "Got to be a good way to go on your motor - no real need for a "full" inlet manifold"

I believe most of the benefit comes from the larger runners and port size. Extrude honing would give another small increase maybe.

 

[Feel]

I meant an expensive full-blown aftermarket one - Dahlback, Monster or Pro-Alloy etc Going for the Sharan one might give you some benefits without blowing a wad on one of those.

Runners on the Sharan one look longer - should help top end?

 

[YerMother]

It is bigger in general, has a larger barrel as well as the wider runners. They start spherical at the barrel and then become oval at the outlets. The actually x-sectional area seems constant however, from inspection anyway.

As you said its probably good for my set-up/power levels and alot cheaper.

First impressions are that spool does seem to have improved and topend does seem stonger. But like i said before could be down to low ambient temps. (it was -2'C when i went out the other night)

 

[Feel]

That's the problem with changing loads of stuff - you must have some logs from last year when it was -2'C, but you can't compare them

 

[wild willy]

I thought it was worth doing. As while i had the head off I ported the inlets to match the large port gasket I got hold of. Which is around 5mm wider either side than the small port!!

This is my project complete now.

I would defo get the forge actuator, drives alot smoother now and boost control is alot better now the wastegate can fully open. Just be sure to get a slightly longer actuator rod (around 10mm) and be prepared th alter the mounting bracket as it doesn't fit properly. I think that this was because our hybrid has a different back plate to the compressor housing due to the larger compressor. I'm using the yellow spring which is said to be 9-15psi

I may right an overall review if i can be bothered after some logs and dyno plots have been done.

Sorry for going a little off topic but, i ordered a forge actuator before christmas and requested it 10mm longer but it came as standard length (my fault probably as i didn't mention hybrid) .
Did you fit it yourself as I'm a little concerned that the screw fixing nearest the actuator (uppermost)will not have enough clearence to be withdrawn fully before clashing with the water feed banjo. Did you suffice with the standard length rod or did you buy a longer length.

 

[YerMother]

It just about clears the water feed banjo. You have to grind the bracket so that it fits flush to the backplate though.