I have this Volvo 240 Turbo CIS Fuel Distributor / dizzy

[switlikbob]

I bought this based on Jrcook's suggestions in FAQ and on his webpage. However, I am confused as to how to hook it up. What is this extra injector looking thing and how do I wire it up? What about the fuel fitting on that injector line? It looks larger than on the BMW one.

[jrcook320]

That is the frequency valve, which you should be able to use the stock one from your '82.

The ports on the fuel distributor, from top left moving clockwise are (take note of the triangle arrows cast into the FD):

1) Main fuel inlet
2) Feed to frequency valve (this is on the opposite side on the 1.8 FD, it's there but not visible in your pic)
3) Fuel return line back to tank (the e21 frequency valve dumps into a T fitting further down the return line)
4) return from WUR
5) (at the 6:00 position now) Feed line to the cold start injector

On the top are the 4 injector lines, and the central port is the feed to the WUR. Again, the cold start injector port and the frequency valve port are in opposite positions on the e21 and volvo units. You'll want to remove the volvo frequency valve and double bango bolt on the main fuel return port, then use the e21 freq valve, banjo bolt and return line. Your stock engine wiring harness already has a plug for the frequency valve. It should reach if you orient the valve correctly.

[switlikbob]

Thank you so much for that information!

[switlikbob]

So JrCook, I found a volvo 240 turbo warm up regulator / WUR ( Bosch PN# 0438140079 ). Do you think this will do the job for me?

[jrcook320]

yes.

[switlikbob]

yes.

Thanks JrCook.

I picked it up. Are you running any kind of aftermarket Fuel Pressure Regulator?

[Layne]

I picked it up. Are you running any kind of aftermarket Fuel Pressure Regulator?

Those are for EFI. All you have to do on CIS is shim the regulator to the pressure you need.

[jrcook320]

No, there's no such thing as an aftermarket pressure regulator that will work with CIS. I have shimmed the stock pressure regulator up to 95 psi, but I don't recommend doing that unless you're also upgrading the fuel pump, as higher pressure will reduce the flow rate of the pump.

I recommend starting with stock fuel pressure, stock volvo 240 control pressure (about 53 psi) and a single boost signal line to the top port on turbo WUR. The on-boost control pressure will drop it to about 43 psi (I posted the numbers I've found here somewhere, I'd have to look it up again to be sure). This may be WAY too low. I know it is on my fuel system, but that will be comparing apples to oranges.

I recently started making a few changes to my tune. I've been running with no boost signal to the WUR for several years with a flat 53 psi control pressure. Just last night I re-connected the boost signal line. Currently, my on-boost CP is set at 48 psi (Adjustment is a high tech process using c-clamps while applying boost pressure with an air compressor while measuring fuel pressure..lol). At a flat 53 psi, I have been getting low 12 AFR's when boost hits (around 12.2-3) that then climbs gradually to 12.5-12.6 by redline. Under highway cruising it will hover around 14.6-14.8 AFR. I've been under the impression this was rich enough for boost, and I could live with the cruising AFR's sometimes dipping slightly rich.

I've read a few things that makes me want to dip into the high 11 AFR's under boost, and I'd like to lean it out a tad on the highway which is why I enabled the boost enrichment again. I leaned my mixture setting out slightly to get my cruise AFR's a little leaner (now around 14.9-15.2), I boosted on it once and my AFR dropped to 11.4 and climbed to 12.5 by redline. That's a wider swing that I would like. I plan to raise the on-boost CP up to 49-50 psi and re-test. I'm hoping for 11.8 at initial boost, maybe leaning out to 12.2-3 by 7k.

I'm also wondering if I bottomed out my sensor plate since it seems to have leaned out more on the top end. Granted, it was cold last night when I tested. I may be dancing a fine line between my mixture setting being too lean and my control pressure being so low that it allows the sensor plate to swing to the end of it's travel. If the weather clears today I'll do some more testing. I think in 70 deg weather I'll be around 11.0 which is way too rich, I don't want to wash the cylinder walls down.

[switlikbob]

I was wondering how a FPR would work with CIS...not possible

So you have no boost / vac line to the top port on your WUR? Or am I confused?

I am planning on swapping all of the volvo cis parts over at once, after I verify that my car runs as it should without the boost turned on. I will be monitoring with my AEM wideband. I am really hoping that becuase I am using all volvo 240 cis parts that this system will work well, once adjusted. I will be more than happy with the 200hp people claim that this system can make.

[jrcook320]

I was wondering how a FPR would work with CIS...not possible

So you have no boost / vac line to the top port on your WUR? Or am I confused?

I am planning on swapping all of the volvo cis parts over at once, after I verify that my car runs as it should without the boost turned on. I will be monitoring with my AEM wideband. I am really hoping that becuase I am using all volvo 240 cis parts that this system will work well, once adjusted. I will be more than happy with the 200hp people claim that this system can make.

You're not confused. I've been running with no boost enrichment signal to the top port of the WUR for several years (ever since I switched to the porsche 924 FD), so my CP has been set to a flat 53 psi. With this configuration, I've been getting around 14.7 AFR while cruising and 12.2-12.5 AFR under boost. Call it dumb luck, perhaps the downdraft AFM is calibrated such that I haven't needed boost enrichment, or perhaps it's the proximity that I put the AFM to the inlet of the turbo, perhaps it's just my combination with higher system pressure and MB injectors. I don't know. I think it's most likely the downdraft AFM and it's proximity to the turbo, it just gets sucked down by the pressure differential.

I've recently determined I want a broader range of cruise/boost AFR's, so last night I hooked it back up and will be tuning to get my on-boost AFR where I want it. At 48 psi CP, I'm too rich under boost. Raising on-boost CP will involve simply pressing the brass plug on the bottom of the WUR in slightly until I get a high 11 AFR under boost.

CIS is amazingly adaptable. As long as your control pressure and system pressure is good and your parts are clean, it will run. You should stay close to the stock volvo control pressure with the volvo fuel distributor, so swapping everything should work well. You should be able to fuel up to 220 hp with the stock volvo system, perhaps more if you upgrade the fuel pump and crank system pressure.

[switlikbob]

Again, thank you for taking the time to write this and for the info. I am still pretty far away from swapping the volvo cis stuff. Right now, I am waiting on some e12 brake system parts to come in from Germany so I can hook up my volvo calipers. Wait a minute, how is my BMW becoming a volvo? LOL! Anyway, once I get the brakes sorted, I have to get some parts welded on the turbo piping, and then get the POS exhaust sorted. Then I can see if the car actually runs right, as it is. Then, I would like to drive it, since I've owned it for almost a year and it has never been on the road.

One more question: What spark plugs and at what gap do you suggest I run with this volvo cis setup? The PO had bosch platinums installed, and I just installed another set of them. The other day, I read that these plugs are a no-no. Thanks! Bob

[jrcook320]

Yeah, I've always read platinum plugs don't clean well on a dirty motor (ie, a high mileage, low tech, mech. fuel injected engine). You're best off just staying with the good ol' bosch supers.

I'm currently running an NGK equivalent to the Bosch WR7DC, which is two heat ranges cooler than the stock 1.8 plug (wr9dc). The 2.0 used the wr8dc, and the 2002 turbo used the wr7dc.

With a bosch red coil and bavauto plug wires I have them gapped at .030". If you go too big the spark won't jump the gap under boost.

[switlikbob]

Okay, I will order some bosch supers, although I prefer the NGK's. I totally know what you are saying with the plug gap and boost. In my M3 I am running NGK R5671A-8's gapped at .020. I had the 7's in there gapped at .022 and motor was blowing out spark.

[switlikbob]

Your stock engine wiring harness already has a plug for the frequency valve. It should reach if you orient the valve correctly.

Is this an unused plug, just dangling?

[Layne]

Is this an unused plug, just dangling?

No, it's plugged intot the frequency valve that you already have. The plug end is white.

[switlikbob]

I just read your thread here JR: http://forums.bimmerforums.com/forum....php?t=1069413

I guess I am going to have to do this as well:

To go with the fuel distributor I recently rebuilt a volvo 240 turbo air flow meter and mounted it to the lower half of a 1.8L E21 air flow meter to allow it to mount to an e21 easily. This setup would be perfect for any guys with a BAE turbo system if you want to up the boost, or if you're leaning out on the top end, or anyone looking into turboing their car in the future.

So no issues mounting the bottom half of the volvo afm to the top half of the volvo afm? If not, maybe I'll get fancy and try my hand at a port & polish job.

[jrcook320]

I just read your thread here JR: http://forums.bimmerforums.com/forum....php?t=1069413

I guess I am going to have to do this as well:


So no issues mounting the bottom half of the volvo afm to the top half of the volvo afm? If not, maybe I'll get fancy and try my hand at a port & polish job.

Are you really asking if you have to bolt the volvo AFM to the bottom half of the 1.8L AFM? If so, yes. How else did you think it installed?

[switlikbob]

LOL, yeah, I guess that was a stupid question.

[EBMW21]

just want to make sure i have this right.




correct?

[jrcook320]

yes.

[EBMW21]

^awesome thx Jrcook you are the CIS man!

[pthm]

Human CIS handbook award goes to JRcook

[shadyduk1979]

just want to make sure i have this right.




correct?

Just for fun, which cylinder is which port?

[Christo19]

Just for fun, which cylinder is which port?

It doesn't matter, all injectors are always going

[shadyduk1979]

It doesn't matter, all injectors are always going

Thats why i said just for fun