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Old 09-27-2010, 06:57 AM   #1
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Default Howto: Mod Crown Vic 1680cc injectors for a BP

Materials
8 x Mazda BP o-rings (fuel rail side)
Flat head screwdriver
Router + grinding disc, optional sandpaper belt, polishing stone



Some Ford Crown Victorias ran such large capacity injectors to accommodate alternative fuels, commonly CNG (compressed natural gas). The injectors are made by Bosch and are identified by a black body with a baby blue, grey, white, or burgundy top. These injectors were also available in most Ford trucks. Remanufactured and rebranded units use all sorts of colors, some (like RC Eng) use their own body shell to try to further differentiate themselves. The injectors we're looking for were offered in CNG configured models from 1996 and up, and were also available on the E-250 & E-350 Econoline, some F-150 & F-250s, and other commercial Ford vehicles. I picked some up from Pick n Pull for less than a crisp $20 and bought a hot dog with the change.

Note: the orange units used in these pics were some extras I pulled from PaP to experiment on. Other than color and flow capacity, they are the same.

Alright, first let's compare our subject injector to a stock 323GTR injector (on right).



The mods performed are simple. The O-ring that fits into the fuel rail on the Ford-fitted Bosch units is too large, and we need to grind some plastic off to ensure enough of the injector fits in the fuel rail. Take off the O-ring using the screw driver as needed.

I started shaving off material on the top injector.


Next, use the cutting disc and/or sandpaper belt to grind down the plastic, up to the second groove. You want to shave it so that it's slightly slimmer than the Mazda BP o-rings we will later fit. Don't go too small, this part of the injector helps keep it stable inside the fuel rail. Shaving too much material will allow it to wiggle and potentially break the seal holding back ~50psi of fuel. Be careful not to puncture the metal, this may also lead to an engine bay fire.

Bosch units using EV1 injector harness connector


Next, use the polishing stone to round-off any bulges, sharp edges, or stray pieces of plastic that can dislodge into the fuel rail or interfere with the seal of the o-rings. Once it's smoothed and debarbed, slip on two Mazda BP o-rings in place of the old one.


Test-fit the injector in your fuel rail. Compare it to a stock unit to make sure they both completely fit the fuel rail. Check for injector play, they should be snug like the stock units. If they aren't, you shaved too much plastic away.

Upgraded Vishnu fuel rail, modified Bosche 1680cc, RC Engineering 550cc, stock 323GT-R 460cc


RC Engineering 550cc, modified Bosche 1680cc, stock 323GT-R 460cc (missing o-ring)



Sources
http://www.rx7club.com/showthread.php?t=693126
http://www.rotaryheads.com/modifications/bosch-1600cc/
http://www.dodgeownerforums.com/smf/...p?topic=6026.0

Where to buy
http://www.rockauto.com/catalog/raframecatalog.php
http://www.atpturbo.com/mm5/merchant...egory_Code=FUL
http://www.theturboforums.com/smf/in...?topic=84766.0
http://motors.shop.ebay.ca/Car-Truck...=p3286.c0.m282
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Old 09-27-2010, 08:26 AM   #2
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Great write-up! valuable info for the DIYer on the cheap
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Old 09-27-2010, 11:14 AM   #3
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The writeup is very nice indeed!

As far as the pictures - you need an eye exam.
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Old 09-27-2010, 01:24 PM   #4
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good lord those are huge injectors
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Old 09-27-2010, 01:32 PM   #5
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Fantastic write up. I am looking into going with some E85 in the future if we get it enough around here. 35 a pop for new injectors is nothing to turn your nose up at either.
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Old 09-27-2010, 02:34 PM   #6
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Thanks everybody. I'm going to PaP today to see if there are any trucks/vans that have the injectors. If I find some, just pay shipping and they could be yours

Quote:
Originally Posted by fooger03 View Post
As far as the pictures - you need an eye exam.
Hahaha, you could be right, it's been a while! Unfortunately all I have is an old phone camera :(
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Old 09-27-2010, 03:53 PM   #7
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How do you tell which trucks/cars have are CNG? I'm pretty sure there aren't any around here (very little CNG used around here)
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Old 09-27-2010, 04:25 PM   #8
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I'm looking at the injector colors, but you could always check out if it has a gasoline cap or a CNG fitting. The word on the net is that some motors came with the 1680cc injectors even though they didn't run CNG. I haven't confirmed nor disproved this yet.
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Old 09-27-2010, 04:43 PM   #9
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Nice writeup. In my hands it would probably be "Howto: Mod Crown Vic 1680cc injectors to set fire to a BP" though.
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Old 09-27-2010, 04:50 PM   #10
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damn. 1680cc is good for a ton of corn.
wish I knew about this when I got my ID's
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Old 09-27-2010, 04:57 PM   #11
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When I go back home for christmas, i am going to pick up my extra block and crank and rods. Then all i have to order is a oil pump and pistons and a 3076 It is gonna be a beast i say. I can't wait to be pumpin some E85 dawg.
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Old 09-27-2010, 06:14 PM   #12
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I would have used my lathe, but I know many people don't have access to such machines. An alternative would be to chuck it in a drill press, and use a file. That helps ensure concentricity
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Old 09-27-2010, 06:23 PM   #13
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No doubt, it'd take no time and they'd be perfect... Everyone should at least have a mini-lathe, they're way more useful then they appear at first glance Also, I'd be glad to turn some down for anyone that wanted me to, I'd only charge a set of injectors, lol... those cars come with 2 sets after all.
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