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Installing On-Board GDI Valve Cleaning Fogger..

Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 27 2020, 10:31pm

PONDERING OPTIONS:
From what I could see initially, there were 3 options to mount the injection nozzle;
1. In front of the throttle body on the atmospheric pressure side, to fog through the throttle blade.

2. Right behind the throttle body on the engine vacuum side, to fog directly into the intake manifold itself.

3. Into the back of the manifold on the engine vacuum side, fogging directly into the main manifold plenum.

After thinking all three of these through, here is the option I chose and why I didn't the others...

1. This is probably the easiest to install, but would likely be the least effective in getting the cleaning liquid evenly distributed to ALL the cylinders. The T.B. blade would never be fully open for long, if at all and the longer the air/liquid path is, the greater chance there is for the liquid to fall out of suspension and puddle. Nixed that idea...! :roll:

2. This method would have been a bit more difficult to install than option #1, due to a hole would have to be drilled/tapped in the T.B. to accept the nozzle, BUT the air/liquid mixture would have probably been more evenly distributed inside the manifold - with or without the throttle blade being open or not.

2b. The biggest potential problem I could see with option #2 is poor air/liquid distribution to the front three cylinders, due to that long inlet tube built into the intake manifold throat and the other weird internal baffles that could make the air separate from the liquid. The first 3 cylinders may likely starve for the cleaning liquid, while the back 5 could get flooded... :shock:

Sooooo, I experimented w/ the original manifold and cut "slots" in the ceiling of the intake tube adjacent to the intake runners of the first 3 cylinders - to provide the air/liquid mixture a more direct path to head-off that potential issue. After looking at that mod for a couple of days and pondering it, I ditched that idea too, because I felt it was too much work and was too invasive to the engine to have to cut an intake manifold like that. Plus, it's a real PITA to get that manifold chucked-up on a Bridgeport squarely to make the necessary symmetrical cuts. Also, didn't want to "short-circuit" the airflow path for those cylinders that might otherwise negatively affect torque and/or disagree with the factory engine calibration. NOT really practical I guess...so, nixed that idea as well! :roll:

3. This option would likely work the best overall, but its the most difficult to install of all three, due to the intake manifold having to be removed! At first, I didn't think there was enough room between the back of the intake manifold and the firewall to allow for an injection nozzle to be installed, but after test-fitting everything with the new manifold temporarily installed and taking some measurements - I discovered that it everything would indeed fit nice and comfortable! Yayyyyy! :D

BINGO! We're in!! :D
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 27 2020, 10:47pm

FITTING THE INJECTION NOZZLE:

I measured the injection nozzle diameter (.393") and discovered it was VERY close to 1/8" NPT pipe tap size, so I measured and selected a drill bit nearest the diameter of the nozzle w/out going over (.342" or 11/32") for drilling the hole in the backside of the intake manifold that accepts the injection nozzle.
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 27 2020, 11:00pm

MODIFYING THE INTAKE MANIFOLD:

After test-fitting the intake manifold onto the engine w/ the injection nozzle placement in mind and taking some measurements - I figured the best place to install the nozzle would be near the middle of the manifold's backside, facing the nozzle forward, toward the incoming air stream in an effort to maximize the air/liquid mixture within the MAIN area of the plenum so ALL cylinders would get a chance to swallow a homogeneous mixture of carbon cleaning chemicals.

Located the place to drill w/ a Sharpie, selected a small pilot drill to get the hole started and stepped-up to the final drill bit to finish. Took my time here and didn't force anything, as I didn't want the intake wall to crack... I was pleasantly surprised how thick the wall of the nylon-reinforced plastic manifold was in this area - which lends itself to being drilled and tapped successfully! :)

In the last picture, you can see the location of the nozzle hole in the intake's back wall, through the intake's inlet throat.
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 27 2020, 11:09pm

Once the hole was drilled, I tapped it w/ a tapered 1/8" NPT pipe tap to just enough depth for the nozzle to screw-in securely. Since it's tapped this way at a taper and there's good thread engagement - the nozzle can never come loose and fall inward into the intake manifold for engine safety. Use patience here and only tap the plastic as much as you need to seat the nozzle.

Test-fitted the nozzle and the hose carrier - everything fit GREAT! So-far, so-good! :)

That's it for today, I'm tired. Sux getting old..... :roll:
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby MIKE91B » Feb 27 2020, 11:37pm

So far I’m on board with your methodology. Based on the flow path in the manifold the rear is the only option for decent distribution in my mind. That long tube that the air enters in would yield bad results for your purpose and in a performance driven application. I cut an LT1 manifold up a few years back. It lends itself to injection prior to the throttle body much better than the truck manifolds. However it yields crap results in real world truck use. Low end torque on an L83 goes to hell.
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 28 2020, 2:00pm

MIKE91B wrote:So far I’m on board with your methodology. Based on the flow path in the manifold the rear is the only option for decent distribution in my mind. That long tube that the air enters in would yield bad results for your purpose and in a performance driven application. I cut an LT1 manifold up a few years back. It lends itself to injection prior to the throttle body much better than the truck manifolds. However it yields crap results in real world truck use. Low end torque on an L83 goes to hell.


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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 28 2020, 2:52pm

INJECTION PROPERTIES:

Here's a couple of short vids that show the spray patterns and delivery of each injection nozzle in the kit. I'm choosing the use of the #3 nozzle to get me started, as I don't want to flood the intake too much and/or quench the combustion process with "too much of a good thing." :lol:

#3 Nozzle, 175ml/min. @ 220 psi. @ 12.8v
https://drive.google.com/file/d/1IxKa9UhhW_7g48mxdhnFnFyNB_gI46wX/view?usp=sharing

#5 Nozzle, 375ml/min. @ 220 psi. @ 12.8v
https://drive.google.com/file/d/1PZ8nSf-vTnD_wWZSwOoUeMgBngSPfxqY/view?usp=sharing
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby nealinator » Feb 28 2020, 3:01pm

The video of #3 looks like there is something spraying off of the side. Is that just due to a temporary connection?

I am enjoying following along with this process you are doing and really like seeing all the pictures and details. Thanks for the sharing!
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 28 2020, 3:09pm

It's just a temporary connection I'm making w/ my fingers for the vid and there is no thread sealant either. :)
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Re: Installing On-Board GDI Valve Cleaning Fogger..

Postby truckdad15 [OP] » Feb 28 2020, 6:14pm

Here is a quick vid of testing the spray pattern within the interior of the intake manifold using the #5 nozzle and same delivery specs as before. Looks to be pretty encompassing and the fog completely saturates the interior upon delivery. I think it'll work pretty good. 8-)

https://drive.google.com/file/d/1_zMj_h8Phr6YsWhE6VeBprBJBP_SeFh4/view?usp=sharing
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